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What is a Laser Diode?A laser diode (injection laser diode, or diode laser) is a semiconductor device that can generate laser light, emitting a narrow light containing a single color, which is similar to a light-emitting diode (LED). The three conditions for generating laser light are: achieving particle number inversion, meeting threshold conditions and resonance conditions. Since laser diodes are extremely electrostatic sensitive, they should be used with care to prevent static electricity. They can be divided into homojunction laser, single heterojunction (SH) laser, double heterojunction (DH) laser and quantum well (QW) laser according to the different PN junction materials.Topics Covered in this GuideLaser Diode Tech Guide in 2021What is a Laser Diode?Laser Diode SpecificationsLaser Diode CharacteristicsLaser Diode ApplicationsHow Does a Laser Diode Work?What is the Laser Diode Symbol?What are the types of Laser Diode?Laser Diode Using TipsHow to Test a Laser Diode?How to Make a Laser Diode?How to Power a Laser Diode?How to Build a Laser Diode Driver Circuit?How to Wire a Laser Diode?How to Select the Right Laser Diode?How to Drive Pulse Laser Diode?What is Power Source of 532 Laser Diode?What is the Difference between Laser Diode(LD) and LED?What is the Wavelength Range of a Laser Diode?Is Diode Laser Permanent?Is LED a Laser Light?How Long do Diode Lasers Last?Can an LED be Used as a Laser?What are the Advantages of Using Laser Diode Instead of an LED?What is the Disadvantage of Laser?FAQsLaser Diode Specifications(1) Wavelength– It is the laser tube working wavelength, including 635nm, 650nm, 670nm, 690nm, 780nm, 810nm, 860nm, 980nm, etc, used for photoelectric switch laser.(2) Threshold Current– The current at which the laser tube starts to generate laser oscillation. For general low-power laser tubes, the value is about tens of mA, and the threshold current of laser tubes with multi-quantum well structure can be as low as 10mA or less.(3) Operating Current– It is the drive current that laser tube to achieve the rated output power, which is more important for the design and commissioning of the laser drive circuit.(4) Vertical Divergence Angle– It is the open angle that the laser diode's light-emitting band in the direction of the vertical PN junction, generally in the 15˚ ~ 40˚ or so.(5) Horizontal Divergence Angle– It is open angle that the laser diode's light-emitting band in the parallel direction with the PN junction, generally in 6˚ ~ 10˚ or so.(6) Monitoring Current– It is the current flowing on the PIN tube when the laser tube is at rated output power. Laser Diode CharacteristicsThe basic structure of the semiconductor laser diode is shown in the figure. A pair of parallel planes perpendicular to the PN junction surface form the Fabry-Perot resonant cavity, they can be the solution surface of the semiconductor crystal, but also can be polished plane. The remaining two sides are relatively rough to eliminate the laser action in other directions than the main direction. In addition, lasers consist of three main components: a lasing medium (solid, liquid or gas), a stimulating energy source (pump) and an optical resonator.Figure 1. Semiconductor Laser Diode StructureOne of the characteristics of laser diodes is the ability to modulate the intensity of their output light directly from current. Because the relationship between output optical power and input current is mostly linear, laser diodes can use analog or digital current to directly modulate the output light intensity, no need for expensive modulators, which makes the diode more economical to use.The most important characteristic of a diode is its unidirectional conductivity, and laser diodes, as one of the diode types, have the same features. In a circuit, current can only flow in from the positive terminal of the diode and out from the negative terminal. The following are specific descriptions.1) Forward FeatureIn electronic circuits, the diode conducts when the positive terminal of the diode is connected to the high potential terminal and the negative terminal to the low potential terminal. In terms of this connection, it called forward bias. In addition, when the forward voltage applied to both ends of the diode is very small, the diode still cannot conduct and the forward current flowing through is very small. Only when the forward voltage reaches a certain value (this value is called the "threshold voltage", about 0.2V for germanium tubes and 0.6V for silicon tubes), the diode can conduct. After it, the voltage across the diode remains basically unchanged (about 0.3V for germanium and 0.7V for silicon diode), which is called the "forward voltage drop".2) Reverse FeatureIn electronic circuits, the positive terminal of the diode is connected to the low potential terminal, and the negative terminal is connected to the high potential terminal. When there is almost no current flowing through the tube, the diode is in the cutoff state. This connection called reverse bias. Diode in reverse bias, there will still be a weak reverse current flow through, called leakage current. When the reverse voltage across the diode increases to a certain value, the reverse current will increase sharply, the diode will lose its unidirectional conductive characteristics, this state is called diode breakdown. Laser diode injection current must be greater than the critical current density, which is related to the temperature of the contact surface and indirectly affects the tube performance, to meet the residence reversal conditions and emit laser. When operating at high temperatures, the critical current increases, reducing efficiency and even damaging the component. Laser Diode ApplicationsAs the most common type of laser products, laser diodes have the advantages of high efficiency, small size and long life, but their low output power (generally less than 2mW), poor linearity and monochromaticity are not good for cable TV system applications, because they cannot transmit multi-channel and high-performance analog signals. Based on the advantages of laser diodes, they play a important role in many applications areas. For example, in the return module of bi-directional optical receivers, uplink transmission generally uses quantum well laser diodes as the light source. Also it is widely used in the computer on the CD-ROM drive, laser printer in the print head, bar code scanner, laser ranging, laser medical, optical communications, laser indication and other small power optoelectronic equipment. The lighting, laser surgery, laser welding and laser weapons and other high-power equipment have laser diodes too.Compared with LEDs, With different light source, lasers are more powerful and operate at faster speeds than LEDs, and they can also transmit light farther with fewer errors. They are also much more expensive than LEDs.Figure 2. Laser DiodeHow Does a Laser Diode Work?Light Emitting PrincipleLight emission in semiconductors is usually caused by carrier complexation. When a positive voltage is applied to the PN junction, it will weaken the PN junction barrier, forcing electrons to be injected into the P region from the N region, and holes to be injected into the N region from the P region. These non-equilibrium electrons and holes injected near the PN junction will be compounded, thus emitting photons of wavelength λ with the following equation.λ=hc/EgWhere: h - Planck's constant, c - speed of light, Eg - band gap width of the semiconductor.The above luminescence phenomenon due to the spontaneous compounding of electrons and holes is called spontaneous radiation. When the spontaneous radiation generated by the photon through the semiconductor, once the electron-hole pair has been emitted near, it can excite the two composite to generate new photons. This photon has been induced to excite the carrier compound and issued a new photon known as excited radiation.If the injection current is large enough, a carrier distribution opposite to the thermal equilibrium state will be formed, that is, the particle number reversal. When the carrier within the active layer in the case of a large number of inversion, a small amount of spontaneous radiation generated by the photons due to the resonant cavity two end reflect and then have induction radiation, resulting in frequency-selective resonance positive feedback, or a gain for a frequency. When the gain is greater than the absorption loss, a coherent light with good spectral lines can be issued from the PN junction, that is, the laser.How Laser Diodes Work?As for Laser diode light-emitting principle, the P-N junction in a laser diode is formed by two doped GaAs layers. It has two flat-ended structures, parallel to a end (highly reflective surface) and a partial reflection. Laser diodes emit coherent light in which all the waves are at the same frequency and phase. The wavelength of the light to be emitted is exactly related to the length of the junction. When the P-N junction is forward biased by an external voltage, the electrons move through the junction and recombine as in a normal diode. When the electrons are compounded with holes, photons are released. These photons hit the atoms, causing more photons to be released. As the forward bias current increases, more electrons enter the depletion region and cause more photons to be emitted. Eventually, some of the photons randomly drifting in the depletion region strike the reflecting surface vertically, thus reflecting back along their original path. The reflected photons are again reflected back from the other end of the junction. This movement of photons from one end to the other is continuous several times. During the photon motion, more atoms release more photons due to the avalanche effect. This process of reflection and production of more and more photons produces a very intense laser beam.Each photon produced in the emission process explained above is identical to the other photons in terms of energy level, phase relationship and frequency. Thus, the emission process gives a laser beam of a single wavelength. To produce a laser beam, the current in the laser diode must be made to exceed a certain threshold level. Currents below the threshold level force the diode to behave as an LED, emitting incoherent light. What is the Laser Diode Symbol?The laser diode symbol used is often the same one used for light emitting diodes in circuit diagrams. It uses the basic semiconductor diode symbol with arrows indicating the generation and emanation of light.Figure 3. Laser Diode Symbol What are the types of Laser Diode?There are several types of laser diodes:✔️Quantum well lasers✔️Quantum cascade lasers✔️External-cavity diode lasers✔️Interband cascade lasers✔️Separate confinement heterostructure lasers✔️DHL (double heterostructure lasers)✔️DFB-LD (distributed feedback laser diode)✔️DBR-LD (distributed bragg reflector laser)✔️FBG (FBG laser diodes laser diodes)✔️VCSEL ( vertical-cavity surface-emitting laser)✔️VECSEL(vertical-external-cavity surface-emitting-laser)✔️MOEMS-LD (micro-opto-electro-mechanical systems laser diode) Laser Diode Using Tips1) laser diode emitted laser light may cause harm to the human eyes. When using, don’t directly watch the light source. It requires warning signs.2) The device needs a suitable drive power supply, the instantaneous reverse current should not exceed 2uA, and the reverse voltage should not exceed 3V. In the power supply on and off, to prevent inrush current. When testing the drive circuit with an oscilloscope, disconnect the power supply and then connect the oscilloscope probe, if the probe is tested under power on, the inrush current may damage the device.3) The device should be stored or worked in a clean environment.4) Working at higher temperatures will increase the threshold current, lower conversion frequency and accelerate the aging of the device. When adjusting the amount of light input, use the optical power meter to detect to prevent exceeding the large rated output.5) The output power works higher than the specified parameters, which will accelerate the aging of the components.The following measures can be taken to slow down device aging.    a. Driving the laser diode with a DC constant current source.    b. Connect a current limiting resistor in series with a bypass capacitor to the laser diode circuit.    c. Since an increase in the temperature of the laser diode will increase the current flowing through it, the heat dissipation measures must be applied to ensure that the device operates within a certain temperature range.(4) To avoid the laser diode breakdown due to withstand excessive reverse voltage, it can be connected in reverse parallel on both ends of the fast silicon diode.(6) The machine needs to be fully dissipated or used under cooling conditions to prevent high temperature use. The output wavelength of the laser is affected by the operating current and heat dissipation, to maintain good heat dissipation conditions and reduce the temperature of the tube core when working.7) Diodes are electrostatic sensitive devices, to take appropriate anti-static measures.Figure 4. Injection Laser DiodeHow to Test a Laser Diode?a. Resistance measurement methodRemove the laser diode, use a multimeter R × 1k or R × 10k file to measure its positive and negative resistances. If normal, the forward resistance value is between 20~40kΩ, and the reverse resistance value is ∞ (infinity). If the measured forward resistance value has exceeded 50kΩ, it means that the performance of the laser diode has declined. If the measured forward resistance value is greater than 90kΩ, it means that the diode has been seriously aged, can no longer be used.b. Current measurement methodUse a multimeter to measure the voltage drop across the load resistor in the laser diode drive circuit, and then estimate the current value flowing through the tube according to Ohm's law. When the current exceeds 100mA, if the laser power potentiometer is adjusted, and no significant change in current, the laser diode can be judged to be seriously aged. If the current increases sharply and out of control, it means that the optical resonant cavity of the laser diode has been damaged.c. Pins DetectionThe laser diode has three pins: LD transmitter, PD receiver, LD-N common1) To distinguish between LD and PD. Use R × 1k block to measure the resistances of laser diode three pins. If a resistance value between the two pins reaches a few thousand ohms, at this time, the black pen is connected to the end of the PD anode, the red pen is connected to the pin for the common terminal, the remaining pin for the LD cathode, so as to distinguish the PD part (bc part of the figure) and LD part ( This distinguishes the PD part (bc part of the figure) and the LD part (ab part of the figure).2) Detect the PD part. PD part of the laser diode is essentially a photosensitive diode, using a multimeter test method is as follows: R × 1k block to measure its resistance, if the forward resistance of a few thousand ohms, the reverse resistance is infinite, it initially indicates that the PD part is good. If the forward resistance is 0 or infinity, it shows that the PD part has been bad. If the reverse resistance is not infinity, it means that the PD part has reverse leakage and the tube quality has become poor.3) Detect the LD part. Use the multimeter R × 1k block to measure the forward resistance of the LD part, that is, the black pen connected to the common terminal b, red pen connected to the a, the forward resistance should be between 10kΩ ~ 30kΩ, the reverse resistance should be infinity. If the measured forward resistance value is greater than 55kΩ, the reverse resistance value of 100kΩ or less, indicating that the LD part has been seriously aging, so the use of the effect will become worse. How to Make a Laser Diode?Step 1: Before made a laser diode, you should clear somethings firstly, including safety equipment, procedures, training in place, as well as disposal etc. Step 2: Build a working laser yourself you start with buying the diode. then you need a lens , and a heat sink , and a powersupply that won't blow it (they're very sensitive) .... all these components are on online, and that's quiet a tricky job ...much easier and cheaper to buy an assembled laser.Step 3: Spend a couple of pounds to purchase a laser pointer, and pull the diode & circuit out of that.Step 4: Don't power it up when it's direction is not firmly fixed away from your eyes, from anyone's eyes , and there might be reflective surfaces on the beam path nearby. Pay attention, do it legally where you are. How to Power a Laser Diode?Laser diodes are operated in forward conduction mode within a specified current range that is optimal for lasing operation, because they are current-driven devices. Laser diode power supplies can operate in one of two modes, constant current (CC) and automatic power control (APC). Most, but certainly not all, smaller laser diodes (5.6- and 9-mm packages) are operated in APC mode. For APC operation, the power supply must have a photodiode mounted inside the laser diode package. How to Build a Laser Diode Driver Circuit?Firstly, you should know that a laser diode driver circuit is a circuit which is used to limit the current and then supplies to the laser diode, and then follow the below steps:Step 1: Have a project with laser diode.Step 2: Find out all the useful parts and their parameters from your project.Step 3. Build the circuits according to the related project schematic.Step 4. Connect the Laser Diode and test it. How to Wire a Laser Diode?According to unidirectional conductivity, laser diodes only allow current to flow in one direction, and they're always polarized. First look at the positive and negative poles of the diode, and then the positive potential is connected to the anode of the diode, and the negative potential is connected to the cathode of the diode. How to Select the Right Laser Diode?Choose a laser diode for your application according to the following steps:Step 1: Turn application requirements into laser parametersStep 2: Selecting the laser typeStep 3: Selecting the laser materialStep 4: Make your final chart and go searching How to Drive Pulse Laser Diode?Laser Diode Driver is to provide current to the laser diode. With the amount of current controlled by the user or some automatic apparatus, you can drive a pulse laser diode. In addition, a laser driver can only regulate the current as long as the laser voltage stays within certain limits, so you should have a check the circuit parameters to select a proper diode driver. What is Power Source of 532 Laser Diode?Check the following table to find out the power source of 532 laser diode:532nm Green Laser DiodePowerPackageDescription0.004WTO-Can- Integrated Photodiode- Compact Size0.005WTurn-Key Module- Compact Size- Long Lifetime0.01WTurn-Key Module- Fiber-Coupled Output- Integrated Photodiode0.1WTO-Can- Integrated Photodiode- Compact Size0.2WTO-Can- Integrated Photodiode- Mode-Hop Supression0.4WButterfly- Integrated Photodiode- Integrated Heater0.5WButterfly- Internal Heater- Integrated PhotodiodeWhat is the Difference between Laser Diode(LD) and LED?LDs and LEDs both emit photons to produce light, but both of them have many differences according to the following table:ParametersLDLEDWorking PrincipleStimulated emissionSpontaneous emissionOmnidirectional emissionFull FormLight Amplification by Stimulated Emission of RadiationLight Emitting DiodeResponseFast response in comparison to LEDSlow responseDriving CurrentRanges from 5 to 40mARanges from 50 to 100mANature of Emitted LightCoherent and MonochromaticIncoherent and consists of various colors.Junction Area during ManufacturingNarrow and small JunctionWide Junction AreaBandwidth RangeRanges from 1MHz to 2MHZRange from10 to 50THzPower to light Conversion EfficiencyApprox 70 %Approx 30%Numerical Aperture of the obtained Light BeamExtremely low as compared to LEDs.Higher in LEDsCostHigh cost and thus used in the specific application.Low cost and thus economicalWhat is the Wavelength Range of a Laser Diode?Diode lasers deliver wavelengths ranging from 810 to 1064 nm. Diode lasers are compact and portable solid-state units. They are used strictly for soft tissue procedures and penetrate 2 to 3 mm or more into soft tissue, depending on the wavelength and tissue biotype. Is Diode Laser Permanent?Diode lasers use a single wavelength of light that has a high abruption rate in melanin. As the melanin heats up it destroys the root and blood flow to the follicle disabling the hair growth permanently. ... Diode lasers deliver high frequency, low fluence pulses and can be safely used on all skin types. Is LED a Laser Light?LEDs typically last longer than lasers, while lasers are faster. ... LEDs have a higher output with wider bandwidths, meaning that they can produce a broad range of less-concentrated light. Lasers have a lesser output and a small bandwidth, produced with a tiny pinpoint of light. How Long do Diode Lasers Last?Typical lifetime of laser diode modules are 25,000 to 50,000 hours. If the laser diode temperature continues to rise exceeding the maximum operating temperature, the diode can be catastrophically damaged or the long term performance may degrade significantly. Can an LED be Used as a Laser?The LED and laser emit light in a relatively narrow range of wavelengths. However, lasers put all their energy in a single wavelength, which emits from a tiny spot. LEDs spread the energy over more wavelengths and send that light from a larger spot into wide cone. What are the Advantages of Using Laser Diode Instead of an LED?It produces a very intense beam of light or infrared radiation which is having following properties. Laser diode used in optical fiber systems are made of gallium arsenide phosphide. The laser having size of grain of sand can produce power output of about 10 mWatt. ON/OFF switching speed of laser is faster than LED. What is the Disadvantage of Laser?Following are the drawbacks or disadvantages of Laser:It is expensive and hence more expenditure to the patients requiring laser based treatments.It is costly to maintain and hence more cost to doctors and hospital management. Increases complexity and duration of the treatment based on laser devices or equipments. FAQs1. Why do we prefer GaAs for laser diode?GaAs advantagesGaAs devices are relatively insensitive to overheating, owing to their wider energy band gap, and they also tend to create less noise (disturbance in an electrical signal) in electronic circuits than silicon devices, especially at high frequencies. 2. What is the advantage of laser over LED?The output power of a 1 watt LED can be < 100 milliwatts. Besides dramatic differences in total output, the laser also offers a significant advantage in terms of how usable that power is to the optical system. Specifically, the laser is a point source of coherent light that produces a well-behaved beam. 3. Why is laser light monochromatic?Monochromatic Laser LightThe light from a laser typically comes from one atomic transition with a single precise wavelength. So the laser light has a single spectral color and is almost the purest monochromatic light available. 4. What happens if the laser diode is forward biased?Forward bias injects charges into the junction, causing spontaneous emission of photons. When the diode is forward-biased, charges are injected into the active area of the junction, while electrons and holes recombine in the junction, creating spontaneous emission of photons. 5. Is a laser diode an LED?Light-emitting diodes (LEDs), like laser diodes, generate radiation via electrical current injection into a junction. LED light comes from spontaneous emission, whereas laser diode light arises from stimulated emission. Thus, LEDs generally have lower output powers and omnidirectional emission.

CatalogⅠ What is a Thermal Fuse?Ⅱ What is the structure of Fuse?Ⅲ How can Thermal Fuses be classified?Ⅳ What are the characteristics of the Thermal Fuse?Ⅴ What are the types of Thermal Fuse?Ⅵ How does a Thermal Fuse work?Ⅶ Precautions for Thermal FuseⅧ Some Frequently Asked Questions about Thermal Fuse Ⅰ What is a Thermal Fuse?A thermal fuse is a new type of electrical overheating protection element. This kind of element is usually installed in heat-prone electrical appliances. Once the electrical appliance fails and generates heat, when the temperature exceeds the abnormal temperature, the thermal fuse will automatically fuse to cut off the power supply to prevent the electrical appliance from causing a fire. The thermal fuse is the same as the fuse we are familiar with. It usually only serves as a powerful path in the circuit. If it does not exceed its rated value during use, it will not fuse and will not have any effect on the circuit. It will fuse and cut off the power circuit only when the electrical appliance fails to produce abnormal temperatures. This is different from a fused fuse, which is blown by the heat generated when the current exceeds the rated current in the circuit.Ⅱ What is the structure of Fuse?Generally, a fuse is composed of three parts: one is the melted part, which is the core of the fuse, which cuts off the current when it is blown. The melt of the same type and specification of the fuse must have the same material, the same geometric size, and the resistance value. It should be as small as possible and consistent. The most important thing is to have the same fusing characteristics. Household fuses are usually made of lead-antimony alloys.  The second is the electrode part, usually two. It is an important part of the connection between the melt and the circuit. It must have good electrical conductivity, should not produce obvious installation contact resistance; third is the bracket part, the melt of the fuse is generally slender and soft, the function of the bracket is to fix the melt and make the three parts a rigid whole for easy installation and use, It must have good mechanical strength, insulation, heat resistance, and flame resistance, and should not be broken, deformed, burned, or short-circuited during use.Ⅲ How can Thermal Fuses be classified?The thermal fuse can be divided into:According to the material: it can be divided into the metal shell, plastic shell, oxide film shellAccording to temperature: it can be divided into 73 degrees 99 degrees 77 degrees 94 degrees 113 degrees 121 degrees 133 degrees 142 degrees 157 degrees 172 degrees 192 degrees... • Commonly used fuse specifications Ⅳ What are the characteristics of the Thermal Fuse?Thermal fuse has the characteristics of accurate melting temperature, high withstand voltage, small size and low cost. The thermal fuse shell is marked with the rated temperature value and the rated current value, it is not difficult to identify, and it is very convenient to use. It can be widely used in electrical equipment, electric heating equipment and practical electrical appliances for overheating protection. Thermal fuse mainly has the following parameters: ①Rated temperature: Sometimes called the operating temperature or fusing temperature, it refers to the temperature at which the temperature rises to the fusing temperature at a rate of 1°C per minute under no-load conditions. ②Fusing accuracy: refers to the difference between the actual fusing temperature of the thermal fuse and the rated temperature. ③Rated current and rated voltage: Generally, the nominal current and voltage of thermal fuse have a certain margin, usually 5A and 250V. Thermal fuse is a one-time-use protection element. Its use affects not only depends on the performance of the element itself but more importantly, on how to select and install the thermal fuse correctly. The thermal fuse is generally connected in series in the circuit when it is used. Therefore, when choosing a thermal fuse, its rated current must be greater than the current used in the circuit. Never allow the current through the thermal fuse to exceed the specified rated current. Before selecting the rated temperature of the thermal fuse, you must understand and measure the temperature difference between the temperature to be protected and the location where the planting fuse is installed.  In addition, the length of the fusing time and the availability of ventilation are also closely related to the selection of the rated temperature of the thermal fuse. Ⅴ What are the types of Thermal Fuse?There are many ways to form a thermal fuse. The following are three common ones:• The first type: Organic Thermal FuseIt is composed of a movable contact (sliding contact), a spring (spring), and a fusible body (electrically nonconductive thermal pellet). Before the thermal fuse is activated, the current flows from the left lead to the sliding contact and flows through the metal shell to the right lead. When the external temperature reaches a predetermined temperature, the organic melt melts and the compression spring becomes loose. That is, the spring expands, and the sliding contact is separated from the left lead. The circuit is opened, and the current between the sliding contact and the left lead is cut off.  • The second type: Porcelain Tube Type Thermal FuseIt is composed of an axisymmetric lead, a fusible alloy that can be melted at a specified temperature, a special compound to prevent its melting and oxidation, and a ceramic insulator. When the ambient temperature rises, the specific resin mixture begins to liquefy. When it reaches the melting point, with the help of the resin mixture (increasing the surface tension of the melted alloy), the molten alloy quickly shrinks into a shape centered on the leads at both ends under the action of the surface tension. Ball shape, thereby permanently cutting off the circuit. • The third type: Square Shell-type Thermal FuseA piece of fusible alloy wire is connected between the two pins of the thermal fuse. The fusible alloy wire is covered with a special resin. Current can flow from one pin to the other. When the temperature around the thermal fuse rises to its operating temperature, The fusible alloy melts and shrinks into a spherical shape and attaches to the ends of the two pins under the action of surface tension and the help of special resin. In this way, the circuit is permanently cut off. Ⅵ How does a Thermal Fuse work?When the current flows through the conductor, the conductor will generate heat because of the resistance of the conductor. And the calorific value follows this formula: Q=0.24I2RT; where Q is the calorific value, 0.24 is a constant, I is the current flowing through the conductor, R is the resistance of the conductor, and T is the time for the current to flow through the conductor. According to this formula, it is not difficult to see the simple working principle of the fuse. When the material and shape of the fuse are determined, its resistance R is relatively determined (if the temperature coefficient of resistance is not considered). When current flows through it, it will generate heat, and its calorific value will increase with the increase of time. The current and resistance determine the speed of heat generation. The structure of the fuse and its installation status determines the speed of heat dissipation. If the rate of heat generation is less than the rate of heat dissipation, the fuse will not blow. If the rate of heat generation is equal to the rate of heat dissipation, it will not fuse for a long time. If the rate of heat generation is greater than the rate of heat dissipation, then more and more heat will be generated.And because it has a certain specific heat and quality, the increase in heat is manifested in the increase in temperature. When the temperature rises above the melting point of the fuse, the fuse blows. This is how the fuse works. We should know from this principle that you must carefully study the physical properties of the materials you choose when designing and manufacturing fuses, and ensure that they have consistent geometric dimensions. Because these factors play a crucial role in the normal operation of the fuse. Similarly, when you use it, you must install it correctly. Ⅶ Precautions for Thermal FuseThe following items must be observed to ensure the normal operation of the fuse:1 Each thermal fuse has rated current and voltage, melting temperature (Tf), operating temperature (Th), and maximum temperature (Tm), which must be used under specified parameters. 2 When selecting the fuse installation location, be careful not to shift the stress to the fuse due to the vibration in the finished product and the displacement of other accessories. 3 It must be installed in a place where the temperature will not rise above the maximum operating temperature after the thermal fuse is blown. 4 Can not be used in liquids or in machines where the humidity is maintained above 95%. 5 The thermal fuse should be installed in a place that can only sense the heat source of the thermal fuse. When it is unavoidable in the structure, a thermal barrier should be installed. For example, when installing on a heater, be careful not to connect directly to prevent the hot wire from heating to the thermal fuse 6 To increase the current flow of the thermal fuse, if it is connected in parallel or continues to pass overcurrent and overvoltage, the internal contact of the thermal fuse will be damaged, which will affect its normal operation. Therefore, it cannot be used under the above conditions. Although the thermal fuse has high reliability in design, the abnormal situation that a single thermal fuse can deal with is limited after all. Coupled with man-made or unpredictable force majeure, the thermal fuse is damaged and cannot function normally, and the circuit cannot be cut off in time when the machine is abnormal. Therefore, when the machine is overheated, when the wrong action directly affects the human body, when there is no circuit cut-off device other than the fuse, and when a high degree of safety is required, two or more thermal fuses with different fusing temperatures should be used. Ⅷ Some Frequently Asked Questions about Thermal Fuse1. How is a thermal fuse different from an electric fuse?An electric fuse is a common name of a thermal fuse. The thermal fuse is of two types.The one which melts at a certain high temperatureThe one which disconnects due to sub-zero temperature as required.Hypo thermal fuse is made of Biometal but a simple electric thermal fuse can be of any metal or alloy.There is another fuse that does not blow but disconnects the electric circuit. This is called a magnetic fuse. This used in circuit breaker. 2. Are thermal fuses universal?If by “universal” you mean “one size fits all”, then no. Thermal fuses come in a range of temperatures. The only ones I’ve bought are to replace failed ones in coffee makers, and I picked ones rated at around 110*C with an appropriate current capacity. Did not search for anything else, but higher current capacity units must exist.For those who have not run into these devices, they operate like any other fuse in that they are installed in series with the power source, but are designed to be relatively insensitive to current and to open when their temperature exceeds the design point. A valuable safety device in heated appliances. 3. How do I test a dryer thermal fuse?First of all, understand that once a certain amount of current goes through any kind of fuse, the fuse blows and can only be replaced, not repaired. So then, the only test you really want to do is to see if the fuse can still conduct electricity. Unplug the power cable and disconnect either end of the thermal fuse. Connect any cheap ohm meter to the loose end and the other end. If you get a reading, you may consider the fuse to be good. Don’t have a meter? In that case, you can use an old flashlight bulb (not LED), along with a battery and a piece of wire to test the fuse. Press the base of the bulb against one node of the battery while pressing the opposite end of the battery to one of the 2 fuse connections. At the same time, hold a test wire between the side of the bulb and the other fuse wire. If the fuse is good, the light will turn on. 4. How do I know if my thermal fuse is blown?Using a digital or analog multimeter, or other resistance-measuring instruments, check the resistance across the thermal fuse (preferably when it’s out of the circuit, which can affect the reading), If you read continuity (in the range of several ohms or less, depending on its rating), the fuse is still functional. If you read an open circuit, the fuse is blown, and has to be replaced. 5. How do you test a fuse using a multimeter?Testing connectivity is the best way of testing a fuse. A fuse works as long as its two terminals are connected by wire i.e. the two terminals of the fuse are shorted. If the connectivity test fails then it is sure that the fuse isn’t working. However, there might arise a case if the fuse isn’t using proper material. There might not be any connectivity, however, testing the resistance between the two terminals would give a small non-zero value. Even in such cases, we say that the fuse is working. However, such cases rarely exist and if they do we don’t consider as a good fuse (at least for the small power applications like a household) 6. What is the function of the thermal fuse of an electric fan?When the oil in the cheap sleeve bearings in the cheap shaded pole motor gets gummy, the motor will start drawing more current and run hotter. If the motor is not re-lubricated in a timely manner, eventually the sleeve bearings will get stuck and the rotor will fail to turn. This results in a locked-rotor condition and the windings draw more current and produce more heat than they can dissipate with no airflow over them to provide cooling. Eventually, the enamel insulation degrades and gets hot enough to smoke, possibly producing shorted turns that draw even more current.  The thermal fuse is a safety device to prevent the cheap motor from actually catching on fire. Sometimes the fuse can be replaced and the bearings can be relubricated to get another year or two of service if the windings haven’t discolored from overheating, but you can be sure that the end is near. You are better off getting a fan motor with sealed ball bearings. They cost more but last much longer, and usually give you a warning by making a rattling noise when the bearings start to wear out rather than seizing silently. 7. What material is used for making electrical fuses and why?Electrical fuses are generally made from materials having low melting. It acts as a low resistance path when the current flowing through it exceeds its rating by even a small amount. This is done to protect an electrical device from getting damaged. Thus, it acts as an overcurrent protection device. During faults, especially short circuit faults, when heavy currents suddenly flow, the fuse wire gets heated up and melts down, thereby preventing damage and fires from occurring. The fuse wires in general are made of nichrome, etc. 8. What is a fuse?It’s a safety device used to provide overcurrent protection of a circuit. Its main component is a metal wire/strip that melts when there’s too much current flowing through it and thus interrupts the current. This element can be made of zinc, copper, silver, aluminum, or some alloys. Fuse body is made of ceramic, glass, fiberglass, molded mica laminates or molded compressed fiber. 9. What is the difference between fuse and circuit breaker?Fuse-it is such a type of device which breaks the circuit one time when overcurrent in the circuit. you cannot break the circuit or open-close according to your choice.Breaker-it is such type of electrical equipment which breaks when overcurrent, other faulty conditions in the circuit. you can easily control the breaker for opening and closing the circuit ut is such a type of automatic switch. Mainly the big breakers are mainly run with the help of a relay. 10. What causes fuses to blow?A fuse is a safety device that should protect the rest of the circuit from (more) damage when there is a FAULT in the circuit. This can be caused by:component failurewiring failureplacing a load in the circuit that exceeds the Circuits safe level.Note that some circuits (example: motors) can have a very large starting current and special (slow blow) fuses are designed for this type of load.

CategoryⅠ IntroductionⅡ Electronic Ballast Circuit Diagram Research Application 2.1 Overview 2.2 Circuit Structure of High-Performance Electronic Ballast       2.2.1 Power Factor Correction Circuit       2.2.2 Inverter Circuit       2.2.3 Lamp Circuit Network       2.2.4 Control Circuit2.3 High-Performance Electronic Ballast Dedicated Integrated Controller of ML4830 Series       2.3.1 Introduction to ML4831/32 Function       2.3.2 The Improvement of the Internal Function of ML48332.4 High-performance Electronic Ballast Built by ML4833Ⅲ FAQ Ⅰ IntroductionIn the 1970s, a worldwide energy crisis emerged. The urgency of energy conservation has led many companies to focus on energy-saving light sources and electronic ballasts for fluorescent lamps. With the rapid development of semiconductor technology, various high-return power switching devices are emerging, which provide conditions for the development of electronic ballasts. In the late 1970s, foreign manufacturers took the lead in launching the first generation of electronic ballasts, which was a major innovation in the history of lighting development. Because it has many advantages such as energy-saving, it has aroused great concern and interest around the world. It is considered to be an ideal product to replace the inductance ballast. Later, some well-known enterprises have invested considerable manpower and material resources to carry out higher-level research and development. Due to the rapid advancement of microelectronics technology, the development of electronic ballasts to high performance and high reliability has been promoted. Many semiconductor companies have introduced a series of products for dedicated power switching devices and control ICs. In 1984, Siemens developed an active power factor correction IC such as the TPA4812 with a power factor of 0.99. Subsequently, some companies have successively launched integrated electronic ballasts. In 1989, Finland's Hell Valley Company successfully launched electronically adjustable ballast monolithic integrated circuit ballasts. Electronic ballasts have been promoted and applied throughout the world, especially in developed countries. Figure 1. BallastChina's research and development of electronic ballasts started late, the technology is not advanced, early understanding of the difficulty and complexity of this product is insufficient, the development of special semiconductor devices has not kept up, the quality of products has not passed, and the market is extremely irregular. A large number of low-priced inferior goods were thrown to the market, causing losses to consumers and seriously damaging the image of electronic ballasts.  In the late 1990s, due to the rapid development and improvement of production levels, from circuit design to electronic components, the products entered a relatively mature stage, and high-quality products entered the construction project. The implementation of China's green lighting project paved the way for the promotion and application of electronic ballasts. Knowledge of Electronic Ballast for Fluorescent Lamps and Germicidal Lamps The electronic ballast is an electronic control device that uses a semiconductor electronic component to convert a direct current or low frequency alternating current voltage into a high frequency alternating current voltage, and drives a light source such as a low pressure gas discharge lamp (sterilization lamp) or a tungsten halogen lamp. The most widely used is the electronic ballast for fluorescent lamps. Due to the adoption of modern soft-switching inverter technology and advanced active power factor correction technology and electronic filtering measures, the electronic ballast has good electromagnetic compatibility and reduces the self-loss of the ballast. Ⅱ Electronic Ballast Circuit Diagram Research Application2.1 OverviewOn October 1, 1997, China's "Green Lighting Project" was officially launched. This is a major decision and measure in the field of lighting technology, which has a huge impact on China's energy, electric light source and lighting technology, and even environmental protection. As an important target of the "green lighting project", China will replace the incandescent lamp with an integrated energy-saving lamp composed of electronic ballasts and compact fluorescent lamps and promote more than 300 million energy-saving lamp, forming the terminal's ability to save 22 billion kWh, which is equivalent to saving about 49-63 billion yuan electricity construction funds. In addition to saving electricity, it can actually reduce social expenditures by 30-40 billion yuan. According to relevant experts from the Ministry of Information Industry, under the same luminous flux conditions, energy-saving lamps can save 80% of energy compared with incandescent lamps, and the cost of purchasing energy-saving lamps can be recovered in the 8-10 months of electricity savings. The use of electronic energy-saving lamps in ordinary households, enterprises and institutions, hotels, restaurants, and commercial systems is more cost-effective than incandescent lamps. However, the old-fashioned inductance ballasts currently working at the industrial frequency generally have the disadvantages of high energy consumption, low efficiency, large volume, and large amount of copper needed. Therefore, the state has set a policy which is to replace traditional inductance ballasts with high frequency electronic ballasts. Currently, some electronic ballasts have appeared on the market, and Table 1 lists the performance comparison of these electronic ballasts. According to the International Electrotechnical Commission standard IEC929 and China's professional standard ZBK74012-90, the electronic ballast should be used in "normal conditions, the lamp should be activated, but it does not cause damage to the lamp performance"; "The shortest time to apply the cathode preheating voltage should not be less than 0.4s" and "the crest factor of the open circuit voltage shall not exceed 1.8; during the minimum warm-up period, no extremely narrow voltage peaks that do not affect the rms value shall be generated", etc.  As listed in table 1, except for high grade electronic ballasts, they are unqualified products. In particular, as early as 1982, the International Electrotechnical Commission (IEC) developed a standard called “interference of household equipment and similar electrical equipment to the power supply system”, namely the IEC555-2 standard. In 1987, Europe also developed a similar EN60555-2 standard. Both standards strictly limit the power factor of the equipment to be close to 1, and it also clearly stated that, all products that do not meet the standards are not allowed to be sold. In view of the great harm caused by the low power factor, it is very important and necessary to impose regulations on the power factor of electronic equipment and products that must be close to 1. Figure 2. Brief Comparison of Low, Medium and High Grade Electronic Ballasts We believe that the high-performance electronic ballast should be a product that has both power factor correction and lamp filament preheating, lighting adjustment and lamp circuit protection, and is fully compliant with IEC555-2 and similar standards. The basic principles of the circuit structure and power factor correction circuit that must be provided for high-performance electronic ballasts are briefly discussed in this article. The integrated controllers for electronic ballasts ML4831, ML4832, ML4833 and high-performance electronic ballast circuits composed of them are highlighted. 2.2 Circuit Structure of High Performance Electronic BallastThe RFI and EMI filters in the figure filter out conducted RF interference and electromagnetic interference from the grid, while obstructing the conducted RF and electromagnetic interference generated by the ballast circuit from entering the grid. The bridge rectifier circuit converts the input AC to DC. The power factor correction circuit acts to improve the input AC current waveform, ensuring that the input current is sinusoidal and in phase with the input voltage, achieving a power factor close to or equal to one.  The inverter circuit completes the conversion of the DC high voltage to the high-frequency AC, and finally transmits the input power to the fluorescent tube through the lamp circuit network. In addition to transmitting electrical power, the lamp network will also perform preheating of the fluorescent filament, sampling and feedback of the lamp operating state signal. The feedback signal of the working state of the lamp is taken from the power factor correction circuit and the dimming signal, and processed by the control circuit to obtain the driving pulse of the switching device in the correct inverter circuit. 2.2.1 Power Factor Correction CircuitThe power factor of the system is defined as PF=γcosφ1 In the formula, γ=I1/IRMS, which is the ratio of the fundamental rms value of the input current to the rms value of the input total current and is also called the distortion factor of the current. φ1 is the phase shift angle of the fundamental current and voltage. If the input voltage of the system has no phase shift (ie, the system is purely resistive) and there is no harmonic component (ie DF=1), the PF of the system must be one. Unfortunately, the input rectification filter units that most of the current devices connect with the power frequency grid are composed of uncontrolled diodes and large-capacity electrolytic capacitors. The instantaneous value of the current on the grid side is quite high (generally about 2 to 3 times that of IRMS), the duration is very short (usually no more than 4ms), and it is severely non-sinusoidal, so the PF of the system is much lower than 1.  The power factor correction is aimed at the drawbacks of the traditional uncontrolled rectifier circuit, and adopts corresponding circuit measures. While increasing the DF value of the system, the phase shift of the input fundamental current and voltage is minimized, and finally the target with the PF value equal to 1 is achieved. As a boost-type active power factor correction circuit commonly used in electronic ballasts, the control circuit uses the input voltage signal as a reference, and the product of the input current and the output voltage signal is used as a modulation source to obtain a sinusoidal pulse width modulation (SPWM) signal to the step-up DC/DC power conversion circuit to adjust the on/off time ratio of the power switch. In the end, a stable DC high voltage is obtained.  The power switching device in the step-up power conversion circuit is driven by the SPWM signal outputted by the control circuit to turn on and off at a high speed, thereby ensuring that the current waveform flowing through the inductor connected in series with the rectifier bridge is a sine wave, and is in phase with the input voltage. Thus, the distortion factors γ=1 and φ1=0 of the system input current are obtained, that is, cosφ1=1, and the system power factor is 1. 2.2.2 Inverter CircuitThe most important function of the inverter circuit is to convert the high-voltage direct current outputted by the power factor correction circuit into a high-frequency alternating current for the fluorescent lamp. The power MOSFET push-pull tubes (V1 and V2) are alternately turned on and off under the driving pulse with a duty cycle of 50%, and is commutated when the current crosses zero in the parallel resonant loop of the power transformer primary inductance and capacitance thus to realize zero voltage switching(ZVS) and perform chopping on high voltage DC. The zero-voltage switching eliminates switching losses associated with output capacitance and parasitic capacitance charging of MOSFET tube, and the gate drive charge is minimal, which helps reduce gate losses.  Since the high frequency AC obtained by the secondary coupling of the power transformer is directly fed to the lamp network, there is no phase shift between the lamp current (ie, secondary current of the power transformer) and the output current of the inverter circuit (ie, primary current of the power transformer). Considering that the total impedance of the lamp network is reduced at high frequencies, and the negative resistance characteristic of the fluorescent lamp itself, it can be found that as the lamp current decreases (corresponding to the weakening of the light intensity of the lamp), the output current of the inverter circuit will increase. 2.2.3 Lamp Circuit NetworkThe lamp circuit network not only needs to deliver the high-frequency AC power to the lamp tube to complete the efficient conversion of electricity and light, but it also needs to implement functions such as filament warm-up, lamp current detection feedback, and auxiliary power supply for the entire electronic ballast system.  The power transformer primary T is connected to the inverter circuit, and the lamp current is directly transmitted to the lamp through the capacitor, and the secondary winding supplies the lamp with filament current for preheating and maintaining the operation. The current transformer TA performs detection and sensing of the lamp current, and sends a signal about the operation of the lamp to the control circuit at any time by the change of the lamp current. The control circuit can judge the light intensity of the lamp according to the magnitude of the lamp current (even including the disconnection and short circuit of the lamp), and then send corresponding control signals to the inverter circuit. 2.2.4 Control CircuitThe control circuit for high-performance electronic ballasts should have a series of functions including power factor correction, lighting adjustment, light-on preheating, lamp disconnection alarm, and lamp restart program control. At present, some integrated circuit controllers for electronic ballasts appearing in the domestic and international device market are mostly based on PFC control, with appropriate addition of lamp control functions, or implementation of lamp control by external circuits. It is worth mentioning that the ML4830/31/32/33 series products can be said to be integrated controllers for high-performance electronic ballasts. 2.3 High-Performance Electronic Ballast Dedicated Integrated Controller of ML4830 SeriesML4830/31/32/33 are integrated circuit controllers developed by American Micro Linear Corporation for high-performance electronic ballasts. The first generation ML4830 has been eliminated; the second generation ML4831 is manufactured by bipolar integrated circuit technology; the third generation ML4832 uses Bicmos process to replace the original bipolar process, the circuit bias current is greatly reduced, and the consumption is greatly reduced. The fourth-generation ML4833 not only adopts the Bicmos process but also has a major improvement in the internal structure, so the function is enhanced and the performance is better. Although these devices can use the functional block diagram of figure 3, the internal structure of ML4831 and ML4832 and the internal structure of ML4833 are respectively shown in figure 4 and figure 5. Figure 3. Functional Block Diagram of ML4831, 32, 33  Figure 4. Internal Block Diagram of ML4831, 32  Figure 5. Internal Structure Block Diagram of ML4833 2.3.1 Introduction to ML4831/32 FunctionThe ML4831/32 is composed of a continuous current type boosting power factor correction stage controlled by an average current. It has a dedicated control circuit for electronic ballasts with various ballast control links. Lamp start-up and restart timing can be achieved by using external circuit components to provide a wide range of control over different types of lamps. The ballast link uses an additional programmable method of frequency modulation and adjustment of the frequency range of the voltage-controlled oscillator to control the lamp power, so it is suitable for various types of output networks. The gain modulator in the ML4831/32 is highly immune to interference caused by switching high-power switching devices. The output of the gain modulator appears as a reference to the current error amplifier at the inverting input of the amplifier. Isine is the current drawn from the AC input; UEA is the output of the error amplifier (pin 1). The output of the gain modulator is limited to 1V. The PWM regulator in the PFC control section compensates for the positive voltage generated by the multiplier output through the negative voltage developed across the pin 4 sense resistor. At the same time, the power MOSFET is protected against high-speed current transients by weekly current limiting. Once the voltage at pin 4 is below 1V, the PWM cycle is terminated immediately. The overvoltage protection (OVP) terminal (pin 18) of the ML4831/32 is used to protect the power circuit from high voltage damage when the lamp is suddenly disconnected. The OVP take-off point can be set by directly tapping the voltage divider resistor to the high-voltage DC bus. As long as the voltage at pin 18 exceeds 2.75V, the power factor correction (PFC) transistor will be turned off and the ballast operation can continue.  The threshold of the OVP should be set to a value that the power device can operate safely, but is not too low to affect the operation of the boost power conversion link. The internal operational transconductance amplifier performs PFC voltage feedback, current sensing and loop amplification. The transconductance amplifier is designed with a low signal forward transconductance so that a large value resistor can be used as a load and a small (<1μF) ceramic capacitor for AC coupling in the compensation network. The compensation network can take the form of figure 6, introducing a zero point and a pole at frequencies fz and fP, respectively: fZ=1/2πR1C1fP=1/2πR1C2 It is noted that the DC-to-ground path and the output of the transconductance amplifier may be out of tune, and the offset error voltage value reflected at the input is determined by uos=iO/gm. Capacitor C1 in figure 6 is used to block DC and minimize the adverse effects of offset. All of the operational transconductance amplifiers in the ML4831/32 incorporate a Slew Rate enhancement to improve recovery under circuit power-up and transient response conditions because the transconductance amplifier changes from a small transconductance state to a large transconductance state. The response to large signals is essentially non-linear. Figure 6. Compensation Network for Transconductance Amplifier The ML4831/32 controls the output power of the lamp by frequency modulation of the non-overlapping conduction of the power switch tube in the inverter part of the ballast circuit. That is to say, during the discharge of oscillation timing capacitor CT, the output of both ballast power tubes is low. The frequency range of the voltage controlled oscillator (VCO) in the device is controlled by the output of the LFB amplifier (pin 6). As the lamp current decreases, the voltage at pin 6 rises, causing the CT charging current to drop, thus causing the oscillation frequency of the oscillator to become lower. Because the ballast output network attenuates high frequencies, the power fed to the lamp increases accordingly. In general, the frequency of the oscillator can be calculated as follows: fosc=1/（tchg＋tdis） Attention: A zero charge current occurs when LFBOUT (pin 6) is high level. Typically, the charge current varies with the two inputs to the oscillator: One is the output of the warm-up timer, and the other is the output of the lamp feedback amplifier (pin 6). During the warm-up phase, the charging current is fixed at a value of Ichg (preheat) = 2.5 / Rset (3). During normal operation, the charging current varies with the voltage of pin 6 from 0 to UOH. When the voltage at pin 6 is zero, the oscillator frequency is lowest and the lamp power is maximum. The discharge current is much larger than the current flowing through the timing resistor RT. For example, when the discharge current is 5 mA, the discharge time is：  tdis ≈ 490 × CT. The ML4831/32 also includes a parallel regulator that limits the UCC voltage to 13.5V. When the UCC is 0.7V lower than 13.5V, the quiescent current of the device will be less than 1.7mA, and the output will be turned off, allowing the device to be started directly using the resistor attached to the rectified AC bus. In addition, because the ML4831/32 contains a temperature sensing function, the ballast operation is stopped as soon as the junction temperature of the device exceeds 120 °C. In order to better utilize the internal sensing function without using an external sensor, the position of the ML4831/32 must be carefully determined on the ballast's circuit board to ensure that the device can properly transfer the operating temperature of the ballast. The chip temperature of ML4831/32 can usually be estimated by the following formula:  Tj=65TA/PD(°C/W) It is worth noting that fully and reasonably using the sensing function inside the device is useful for reducing the total cost of the ballast. The starting scheme of the device is specifically designed for the ML4831/32 in accordance with the principle of ensuring the longest lamp life and minimizing the ballast heating. Figure 7(a) contains a starting scheme including preheating of the filament and sudden breaking of the lamp. When the ballast is energized, the time that the voltage on the CX rises from 0.7V to 3.4V is called the warm-up time of the filament.  During this time, the oscillator's charging current Ichg = 2.5/Rset, the oscillator produces a very high frequency, but does not produce a voltage sufficient to start the lamp. After the filament is preheated, the frequency of the inverter circuit drops to a minimum, and a high voltage is generated to start the lamp. If the voltage of the inverter circuit does not jump when the lamp should start to work, the lamp feedback voltage entering pin 9 will rise above Uref, the CX charging current will be bypassed, and the inverter circuit will stop working until CX drops to a 1.2V threshold by RX discharge. Stopping the inverter circuit in this way can avoid the failure of the lamp to start or the inverter circuit to overheat when it is disconnected from the socket.  In general, it is better to choose a large resistance RX to make this period longer. When CX reaches the 6.8V threshold, the oscillator will turn off LFBOUT, so the lamp will be driven to full power, then dimmed, and the potential of the CX pin is clamped at approximately 7.5V. The whole process is shown in the waveform of figure 7(b). Figure 7. Lamp Start Preheat and Interrupt Timing Scheme and Its Waveform 2.3.2 The Improvement of the Internal Function of ML4833The ML4833 is a modified version of the ML4831/32. In addition to the full functionality of the ML4831/32 described above, the most prominent improvement is in the power factor correction section. The power factor correction part of the ML4833 is a step-up type PFC control circuit for peak current sensing. This form of circuit only requires voltage loop compensation, which is simpler than the ML4831/32 with average current control mode circuit. It consists of a voltage error amplifier, a current sense amplifier without compensation, an integrator, a comparator, and a logic control circuit.  In the boost type power conversion part, the correction of the power factor is performed by the current sensing resistor to output the sensing voltage and the current flowing through, and the duty ratio is adjusted by comparing the integrated voltage signal of the error amplifier with the voltage across the Rsense. The control timing of the duty ratio is as shown in figure 8. Considering that all of the high-performance electronic ballast integrated control chips of Micro-Linearity are packaged in 18-pin DIP or SOIC packages, the improvement of the device structure will inevitably bring about changes in the internal functional frame and external pin functions. Figure 8. PEC Link and Duty Cycle Control of ML4833 2.4 High-performance Electronic Ballast Built by ML4833Figure 9 shows the complete circuit diagram of a high-performance electronic ballast built by ML4833. The circuit is a typical AC/DC/AC structure: the RFI suppression filter circuit is added to the input terminal, the booster active power factor correction circuit is composed of AC/DC in the front stage, and the high-frequency inverter circuit is composed of DC/AC in the rear stage. A closed-loop is formed through T5, VD11, R23 and pin 8 of the control to make the system works stably. Figure 9. Complete Circuit Diagram of High-performance Eectronic Ballast Built with ML4833  Ⅲ FAQ1. What is the use of electronic ballast?An electronic ballast will convert power frequency to a very high frequency to initialize the gas discharge process in Fluorescent Lamps – by controlling the voltage across the lamp and current through the lamp. 2. What is the output voltage of an electronic ballast?This unit operates off the AC mains with a voltage of 230 Volts and voltages generated within the unit can reach 600 to 800 Volts. 3. What is inside an electronic ballast?Lighting ballasts generate an initial high voltage to start the arc that excites the gases in fluorescent and HID lamps and makes them shine. ... Lighting ballasts for fluorescent light bulbs and HID lamps made before 1980 may contain polychlorinated biphenyls (PCBs). 4. How do you make an electronic ballast for tube light?An electrical ballast is nothing but a simple high current, mains voltage inductor made by winding number of turns of copper wire over the laminated iron core. Basically, as we all know a fluorescent tube requires a high initial current thrust to ignite and make the electrons flow connect in between its end filaments. 5. How do you wire an electronic ballast?Connect the ballast to the power from the breaker panel by wiring the black wire from the breaker panel to the black wire on the ballast, using a wire nut. Connect the white wire from the breaker to the white wire from the ballast. 6. What's the difference between electronic and magnetic ballast?A magnetic ballast uses coiled wire and creates magnetic fields to transform voltage. ... An electronic ballast uses solid-state components to transform voltage. It also changes the frequency of the power from 60 HZ to 20,000 HZ or higher depending on the ballast. 7. How do you test an electronic ballast with a multimeter?Insert one probe of the multimeter into the wire connector holding the white wires together. Touch the remaining probe to the ends of the blue, red and yellow wires leading from the ballast. Depending on the ballast, you may have only red and blue wires. 8. Are electronic ballasts non-linear loads?Rectified input, switching power supplies and electronic lighting ballasts are the most common single-phase non-linear loads. 9. Which is not the advantage of electronic ballast?Electronic ballasts are more efficient and more compact in size and weight. They also provide the ability for continuous power adjustment in different settings. A disadvantage is that power fluctuations may cause a failure but this can be offset by adding a buffer capacitor. The operation of the ballasts generates heat. 10. Can you repair an electronic ballast?I eventually replaced the 2 switching transistors in this ballast as well and it worked. So the next time you have a problem with an electronic ballast from a fluorescent fitting open it and check before buying a new one. They can be expensive and more often than not they can be repaired. 

Ⅰ IntroductionA differential transformer is an electromagnetic inductive displacement sensor that converts mechanical displacement into an electrical signal. It mainly relies on the displacement of the movable iron core in the cylindrical coil and establishes a mutual induction relationship between the input coil and the output coil of the cylindrical coil, and the displacement of the movable core can be obtained by measuring the induced voltage of the output coil proportional to it.  CatalogⅠ IntroductionⅡ The Working Principle and Structure of the Differential TransformerⅢ The Type of Differential TransformerⅣ Linearity and SensitivityⅤ The Cause of the ErrorⅥ The Measurement Circuit  6.1 Differential DC output circuit  6.2 DC differential transformer circuitⅦ The Application of Differential TransformerⅧ Application Circuit Examples of Differential Transformer  8.1 MZK-4R Grinding Machine Automatic Control Device  8.2 ZD41B Short Cylindrical Roller Sorting Machine  8.3 Discussion of Differential Transformer ApplicationⅨ FAQ Characteristics of Differential Transformer(1) There are many types of linear ranges, and it is easy to select according to the use. Usually, there are about 10 types between ±2 mm and ±200 mm.(2) The structure is simple, so the vibration resistance and impact resistance are strong.(3) It does not wear, does not deteriorate, and has excellent durability.(4) The output voltage has a precise ratio to the displacement of the core, that is, the linearity is good. Generally, the full stroke deviation of this sensor is less than 1%, and it can be guaranteed to be ±0.2% to ±0.3% in high-grade products.(5) Because of the high sensitivity, a large output voltage can be obtained, and a small displacement can be detected without requiring an advanced circuit.(6) Since the output changes smoothly, high-resolution detection is possible.(7) The zero point is stable, and its use as a reference point for measurement is good for maintaining accuracy.(8) A high response speed from 500 Hz to 100 Hz can be obtained. Ⅱ The Working Principle and Structure of the Differential TransformerThe structure of the differential transformer is divided into two types: variable-gap type and solenoid type. Since the variable-gap type differential transformer has a small stroke and a complicated structure, it is rarely used at present, and the solenoid type is usually adopted. The basic components of the solenoid type differential transformer include an armature, a primary coil, a secondary coil, and a coil frame. The primary coil acts as excitation and corresponds to the primary side of the transformer. The secondary coil is formed by inverting two coils of the same structural size and parameters to form the secondary side of the transformer. There are two-section, three-section and multi-section according to the initial and secondary arrangement. The zero potential of the three-section is small, the two-section is more sensitive than the three-section, and the linear range is large. The four-section and five-section are all efforts to improve the linearity of the sensor. The working principle of the differential transformer can be explained by the principle of the transformer. The difference is: the general transformer is the closed magnetic circuit, and the differential transformer is the open magnetic circuit; the mutual inductance of the original transformer and the secondary side is constant, and the mutual inductance between the primary and secondary sides of the differential transformer changes as the armature moves. The operation of the differential transformer is based on the change of mutual inductance. The construction principle of the differential transformer is as shown in figure 1, and is composed of a cylindrical coil and a core that is completely separated from it. A typical differential transformer has three cylindrical coils, each of which is one-third of the total length, with a primary coil in the middle and a secondary coil on each side. The iron core added to the cylindrical coil is used to link the magnetic lines of force in the coil to form a magnetic circuit. Figure 1. The Construction Principle of the Differential Transformer When an alternating voltage is applied to the primary coil in the middle (ie, excitation), an electromotive force is generated due to the mutual inductance with the coils at both ends (this is the same as that of a normal transformer). Since the secondary coils are connected in series with each other in opposite polarity, the induced electromotive forces in the two secondary coils are opposite in phase, and as a result of the addition, a potential difference between the two is generated at the output end. At the center of the coil length direction, the induced voltages of the two secondary coils are equal in opposite directions, and thus the output is zero. This position is called the mechanical zero point of the differential transformer (or simply zero points). When the iron core changes position from zero points to a certain direction, the voltage of the secondary coil in the displacement direction increases, and the voltage of the other secondary coil decreases. The product design guarantees that the potential difference is proportional to the displacement of the core. When the iron core moves from zero points to the opposite direction, a proportional voltage is generated, but the phase is 180° different from the previous one. The relationship between the secondary coil voltage and the output voltage difference with respect to the core displacement is shown in figure 2. The range in which the voltage difference is proportional to the core displacement is called the linear range, and its proportionality is called linearity, which is the most important indicator of the differential transformer. Figure 2. The Core Displacement — Output Relationship of Differential Transformer Ⅲ The Type of Differential TransformerThe standard differential transformer consists of a cylindrical coil and a rod-shaped iron core. In actual use, there is also a structure with a guide and a spring. The basis for the classification of differential transformers is as follows: • According to the voltage input to the primary coil(excitation type)Commercial power supply type is suitable for practical measuring instruments of 50-60Hz, 6.3V power supply excitation;Oscillation power supply type is an excitation circuit of 1~5KHz, it is suitable for application measuring instruments requiring certain accuracy and response characteristics;DC power supply type, the semiconductor device is installed in the coil part of the differential transformer to form the excitation oscillation circuit and the secondary output detection circuit inside the coil. It is a differential transformer whose input and output are both DC, called DC-DT. • According to the displacement range of the iron core (displacement type)Small displacement type considers how to measure the small displacement below 0.5mm from the structure;General displacement type is designed for measuring the displacement about 100mm or less;The long-stroke type is designed for long stroke measurement of 120 to 400 mm.  • According to the use environment (environment type)Standard type is used in a normal environment with a temperature of -30℃ to +90℃ and a humidity of about 80%;Environmentally friendly type is the sensor for high temperature, high humidity, waterproof and radioactive environments. Features and SpecificationsWhen using a differential transformer as a position sensor, the selected specifications are as follows:◆ Excitation power supply (frequency, voltage, waveform, etc.);◆ Structure (whether guides and springs are required);◆ Linear range (it is usually ±1%, and that of high-grade products is ±0.5%～±0.2%);◆ Sensitivity (corresponding to the output of the core displacement of 1mm);◆ Impedance (input, output impedance);◆ Connection conditions (cables, sockets, input circuits, etc.);◆ Assembly method (connection method with the object to be tested, etc.);◆Environmental conditions (temperature, humidity, dust, water resistance, rust-proof conditions, etc.). Ⅳ Linearity and Sensitivity• Linearity. The linear range of the differential transformer is affected by the non-uniform magnetic field of the solenoid coil. A reasonable design guarantees the required linear range and linearity.• Sensitivity. The sensitivity of the differential transformer refers to the change of the output potential generated by the armature unit displacement. It can be expressed by mV/mm. In practice, considering the influence of the excitation voltage, it is also commonly expressed by mV/mm/V, that is, the potential change generated by the armature unit displacement divided by the excitation voltage value. The sensitivity of the differential transformer is related to the primary voltage, the number of secondary winding turns, and the frequency of the excitation voltage:• Relationship with secondary turnsThe number of secondary turns increases and the sensitivity increases, which is linear. However, the number of secondary turns cannot be increased indefinitely because the residual voltage at the zero points of the differential transformer also increases.• Primary voltageThe sensitivity is proportional to the primary voltage, but the primary voltage should not be too large. When the voltage is too large, the differential transformer coil will heat up and cause the output signal to drift. Generally, 3~8V is used.• Excitation power frequencyWhen the frequency is very low, the sensitivity increases with increasing frequency; when the frequency increases, the inductance of the coil is much higher than its resistance, the sensitivity is independent of the frequency; when the frequency exceeds a certain value (the value varies depending on the armature material), the effective resistance of the wire increases due to the skin effect of the wire at a high frequency, and the eddy current loss and hysteresis loss of the armature increase, and the output decreases. Figure 3 is the relationship between the input frequency and sensitivity of a certain magnetically permeable material, which can be used as a reference for selecting the excitation frequency. Figure 3. Relationship Between Excitation Frequency and Sensitivity of Differential Transformer Ⅴ The Cause of the ErrorThe error refers to the deviation between the actual and ideal characteristics of the sensor. Here, the system error inherent in the sensor itself and random error is mainly analyzed, and the error in the measurement method is not involved.• Influence of amplitude and frequency of excitation power supplyFluctuations in the magnitude of the excitation supply voltage cause changes in the strength of the excitation field of the coil to directly affect the output potential. The frequency fluctuations have little effect.• The effect of temperature changesChanges in ambient temperature cause changes in the magnetic permeability of the coil and the magnet, causing a change in the magnetic field of the coil to cause temperature drift. This effect is more severe when the coil quality factor is low. The use of constant current source excitation is more advantageous than the constant voltage source. Properly increasing the quality factor of the coil and using a differential bridge can reduce the effects of temperature.• Zero residual voltageWhen the armature of the differential transformer is in the neutral position, the ideal output voltage should be zero. But in fact, when using a bridge circuit, there is always a small voltage value (from a few millivolts to tens of millivolts) at zero point, which is called the zero residual voltage. Figure 4 is an enlarged output characteristic of the zero residual voltage. The dotted line is the ideal characteristic and the solid line indicates the actual characteristics. The presence of a zero residual voltage causes an insensitive zone near the zero point. Figure 4. Zero Residual Voltage of the Differential TransformerThe waveform of the zero residual voltage is very complicated and irregular. It is analyzed to include the fundamental wave in-phase component, the fundamental wave orthogonal component, and the second and third harmonics as well as the electromagnetic interference waves with small amplitude. The reasons why the zero residual voltage is generated are as follows:• Fundamental wave component: Since the winding of the two secondary windings of the differential transformer can not be completely identical in process, its equivalent circuit parameters (mutual inductance, self-inductance and loss resistance, etc.) cannot be completely equal, thus two induced potential values are not equal. The copper loss resistance of the primary coil, the iron loss and material non-uniformity of the magnetically permeable material and the presence of the inter-turn coil capacitance cause the excitation current to be out of phase with the generated magnetic flux.The above factors cause the induced potentials in the two secondary coils to be not only unequal in value but also in phase. The zero residual voltage generated by the difference in phase cannot be eliminated by adjusting the armature displacement. • High-order harmonics: The high-order harmonics are mainly caused by the nonlinearity of the magnetization curve of the magnetically permeable material. Due to the effects of hysteresis loss and magnetic saturation, the excitation current is inconsistent with the magnetic flux waveform, resulting in a non-sinusoidal wave (mainly the third harmonic flux), thereby inducing a non-sinusoidal potential in the secondary winding. The general method for eliminating zero residual voltage:— From the design and process, try to ensure the symmetry of the coil and the magnetic circuit. The structure can adopt the magnetic circuit adjustment mechanism; when selecting the working point of the magnetic circuit, it should be ensured that the magnetic field does not work in the saturation region of the magnetization curve.— Use the appropriate measurement line. The phase-sensitive detection circuit can not only identify the moving direction of the armature but also eliminate the high-order harmonic zero residual voltage of the armature in the middle position. As shown in figure 5, after using the phase-sensitive detection, the characteristic curve of the armature reverse stroke changes from 1 to 2, thereby eliminating the zero residual voltage. Figure 5. Output Characteristics After Phase-sensitive Detection— Use compensation lines. In applications of a differential transformer, there are many circuit types used to eliminate the zero residual voltage, which can be summarized as follows:▲Add series resistors to eliminate the in-phase component of the fundamental wave; generally the resistance of the series resistor is very small such as 0.5~5Ω, and is wound with constant wire.▲Add parallel resistors to eliminate the fundamental wave orthogonal component, but it has an effect on the in-phase component of the fundamental wave; the resistance of the shunt resistor is from tens to hundreds of kiloohms.▲Shunt capacitor, change phase shift, and compensate for high-order harmonics; parallel capacitor value is in the range of 100 ~ 500pf.▲Add feedback winding and feedback capacitor to compensate for fundamental wave and high-order harmonics.In fact, these values are determined experimentally; based on the working principle of the differential transformer and the cause of the zero residual voltage, the above methods can be modified and combined, and it is also possible to design a new compensation circuit. Figure 6 shows some line schematics for compensating for zero residual voltage for reference. Figure 6. Zero Residual Voltage Compensation Circuit of Differential Transformer Ⅵ The Measurement Circuit6.1 Differential DC output circuitThe output voltage of the differential transformer is an AC signal whose amplitude is proportional to the armature displacement. If the output value is measured with an AC voltmeter, it can only reflect the magnitude of the armature displacement and cannot reflect the direction of the displacement. Secondly, there is a certain zero residual voltage in the AC voltage output. Even with various compensation methods, it can only be reduced and cannot be completely eliminated. Therefore, the DC output circuit is commonly used in engineering practice, which can reflect the displacement direction of the armature and compensate for the zero residual voltage. The DC output circuit has two forms: one is a differential phase-sensitive detector circuit, and the other is a differential rectifier circuit.The differential rectifier circuit is shown in Figure 7. This circuit is relatively simple. It does not need to compare the voltage windings. It does not need to consider the influences if the phase adjustment and the zero residual voltage. The influence on the sensing and distributed capacitance can also be ignored. In addition, since the rectifying portion is on the differential output side, the two DC conveying lines are convenient to connect, and can be transported at a long distance, and are widely used. Figure 7. Differential Rectifier Circuita) full-wave current output         b) half-wave current outputc) full-wave voltage output         d) half-wave voltage outputDifferential phase sensitive detector circuits come in many forms. Figure 8 shows two examples, one is a full wave circuit and the other is a half-wave circuit. The phase sensitive detector circuit requires that the comparison voltage and the secondary transformer output voltage of the differential transformer have the same frequency and the same phase or opposite phase.  To ensure this, a phase-shifting circuit is usually connected to the circuit. In addition, it is required that the comparison voltage amplitude should be as large as possible (because the comparison voltage acts as a switch in the detector circuit, and if it is less than the signal voltage, the switch cannot be turned on), generally it should be 3 to 5 times the signal voltage. In the figure, Rw is the bridge zero potentiometer. For the case of measuring small displacements, since the output signal is small, the input amplifier is also connected to the circuit. Figure 8. Differential Phase-sensitive Detection Circuita) full-wave detection         b) half-wave detection6.2 DC differential transformer circuitThe working principle of the DC differential transformer is exactly the same as that of the ordinary differential transformer described above. The only difference is that the power supply used in the instrument is a DC power supply (dry battery, battery, etc.). The schematic diagram of the DC differential transformer is shown in figure 9. It consists of a DC power supply, a multivibrator, a differential rectifier circuit, a filter and so on. Figure 9. Schematic Diagram of DC Differential Transformer CircuitThe multivibrator provides a high frequency excitation power supply for the differential transformer, which can be a square wave, a triangular wave or a sine wave. DC differential transformers are commonly used in the following applications:◆ The measuring point is far from the control room (more than 100m);◆ Simultaneous use of multiple differential transformers and requires no interference with each other and with other equipment;◆ Where explosion protection is required;◆ Requires easy to carry, such as working in the field. Ⅶ The Application of Differential TransformerDisplacement measurement is the most important use of differential transformers. Any physical quantity that can be transformed into a displacement can be measured with a differential transformer. It is noted that the differential transformer measurement is generally contact type. In some cases, it will affect the state of the measured object (such as vibration), which is the so-called “load effect”. In this case, other types of sensors must be used such as eddy current sensors, etc.◆ It can be used as the main component of many precision measuring instruments, such as making high-precision inductance comparator with corresponding measuring devices, which can perform various precise measurements on parts: length, inner diameter, outer diameter, non-parallelism, non-flatness, non-perpendicularity, vibration, eccentricity, and ellipticity.◆ As the main measuring part of the bearing rolling element automatic sorting machine, it can sort large and small steel balls, large and small cylinders, large and small round vertebrae, needle roller and so on.◆ It is used to measure the expansion, elongation, strain, movement, etc. of various parts. With a variety of sensors, its displacement measurement range can be from ±3μm to over 1000mm.◆ Vibration and acceleration measurements. An accelerometer for measuring vibration can be constructed by using a differential transformer and a cantilever beam elastic support.◆ Pressure measurement. The differential transformer and the elastic sensitive component (diaphragm, bellows, spring tube, etc.) can be combined to form a pressure sensor of the open-loop system and a force-balanced pressure gauge of the closed-loop system. Due to the excellent characteristic of differential transformer as the displacement sensor, it has been applied in almost all industrial fields and several specific examples are described below.• Steel industry: blast furnace top-level detection, continuous casting roll gap, sand type vibration, convexity detection, position detection of sliding water nozzles such as ladle and tundish.• Heavy motor industry: the main valve of the steam turbine, the valve lift detection of the bypass valve, and the posture monitoring of the elevator.• Construction machinery industry: Measuring head for numerical control machine tool simulation test.• Ceramic industry: thermal expansion testing of refractory materials, shape detection of templating glass.• Ship and vehicle industry: fuel classification position detection of diesel engine, dynamic characteristic detection of fuel injection valve of an automobile engine, and eccentricity detection of tire and wheel.• Weighing machine industry: a device that automatically measures the weight of the bag, and a weighting machine for the asphalt carrying device.• Measuring instrument, testing machine industry: used for traction test, creep test of metal materials and plastics, signal conversion part of flow meter and liquid level meter, a mechanical test of civil building components.• General industry: spacer separators for assembling bearings, motion deviation detection during stamping, and measurement of workpiece size and shape deviation. Ⅷ Application Circuit Examples of Differential Transformer8.1 MZK-4R Grinding Machine Automatic Control DeviceThis device is used on automatic or semi-automatic grinding machines. During the grinding process of the workpiece, the control device can accurately output 4 signals according to the amount of the pre-regulation to control the introduction of the grinding head, rough grinding, fine grinding, light grinding and exit, etc., thus realizing the automatic measurement and control of the grinding process. • Working process of the grinding machineWhen the workpiece is loaded, the measuring device first enters the workpiece for measurement. If the workpiece size meets the pre-adjusted result, the control device sends a “starting” signal, the grinding head enters the workpiece and moves forward quickly to the machining direction, and coarse grinding starts. Taking the internal grinding as an example, as the workpiece size of the grinding wheel becomes smaller, the output signal of the measuring head also becomes smaller.  When the preset position is reached, the trigger sequentially sends three signals, that is, the “rough grinding end” signal, indicating that the rough grinding is finished, so that the moving speed of the grinding wheel is reduced, and the fine grinding starts; when the fine grinding is finished, the “finishing end” signal is issued, so that the grinding wheel stops moving and the light grinding starts; when the preset size is reached, the “light grinding end” signal is issued to make the grinding wheel and the detection device exit quickly. • Working principle of measuring head (sensor)The measuring head adopts a differential transformer type displacement sensor, and its structure is as shown in figure 10(a). The iron core moves to the right, so that the induced potential of the winding A decreases, and the induced potential of the winding B increases (and vice versa). The two windings and the resistors R1 and R2 in the measuring device form a bridge to realize differential output, as shown in figure 10(b). Figure 10. Schematic Diagram of the Differential TransformerThe primary coil is excited by a square wave generator with a square wave frequency of 3 kHz and an effective voltage value of 3.5V. Along with the change of the displacement of the core, a corresponding voltage variable is generated between the boom of the potentiometer Rw and the secondary common tap (ground) of the measuring head. The displacement-voltage characteristic curve in figure 11 is obtained after the voltage variable is amplified and phase-sensitive rectified. Figure 11. Output Characteristic Curve of Differential TransformerIn the figure, the S-T segment is the full linear range, wherein the H-E segment (high precision) is the ×1 gear indication range, and the K-C segment (low precision) is the ×10 gear indication range. The“start”signal 0 is sent in the D-A segment, the“rough grinding end” signal 1 is sent in the G-B segment, and the“fine grinding end” signal is 2 sent in the 0-F segment. The“light grinding end”signal 3 is sent at point 0. • Principle of the circuit①The circuit block diagram shown in figure 12. Figure 12. Circuit Block Diagram of Control Device②Explanation of the circuit principleThe device consists of six parts: ▲Input bridge, the two arms are composed of two secondary windings of the measuring head, the other two arms are composed of R84 and R85, the potentiometer VR1 is used for the electrical zero points coarse adjustment, the VR2 is used for the zero points fine adjustment, and the R86 is used to limit the zero point adjustment range.In order to obtain the reference voltage for amplifier calibration, a voltage is obtained by the square wave generator, and another bridge is formed by transformers TR4, R88, and R89, and VR4 is used to adjust the reference voltage. ▲The amplifier amplifies the weak signal obtained in the input circuit to have sufficient amplitude to complete the measurement and control. T15, T17, and T18 form a voltage amplifier with gains of about 10, 20, and 20 dB, respectively. T16 is a buffer stage. T19 and T20 form a push-pull power amplifier stage, and the voltage gain of the amplifier is about 60 to 70 dB. In order to achieve higher stability and linearity, deeper negative feedback is added to each stage. The negative feedback of first stage is adjustable, and the total gain of the amplifier is adjusted by VR3. ▲Phase-sensitive rectification and indicating circuit are used to complete the rectification and identify the phase of the input signal. The half-wave rectification circuit is composed of D15 and D16, and the blocking voltage is 13V, which is provided by the square wave generator.The rectified DC ramp signal is used as an input to the trigger on the one hand and as a panel indicator on the other. The μ meter is a microampere meter with a full-scale of 150μA, and full-scale indications of 50μ and 500μ are obtained with shunt resistors R90 and R91. D33 is used as a voltage clamp to protect the meter head. ▲Square wave generator, which is used to generate the excitation voltage required by the measuring head and the blocking voltage required for phase-sensitive rectification. The high rectangular coefficient multivibrator circuit is composed of T21 and T22, which is easy to start, high in frequency and amplitude stability, and its oscillation frequency is 3 to 3.5 kHz. ▲Trigger, according to the comparison of the output voltage of the phase-sensitive rectification and the pre-adjustment voltage, four different control signal outputs are sequentially generated. The circuit adopts a trigger with an emitter coupled by a Zener tube, which has a small temperature drift and convenient backlash adjustment. Among them, VR5, VR6, VR7, and VR8 are used as the adjustment potentiometers for the four signals of “0”, “1”, “2”, and “3” on the panel. ▲Power:-24V, used for power relay after rectification and filtering;-15V, generated by the series regulator circuit and is used as the collector voltage of each transistor and the trigger pre-call;+6V, generated by the shunt regulator circuit and is supplied for the bias and pre-call of the trigger. • Main technical indicators✿ Instrument indexing and error:High precision (G) 1μ/division; full scale -10～+50μ; error ≤1.5μLow precision (D) 20μ/division; full scale -100～+500μ; error ≤30μ✿ Adjustable range of control signal :Signal "0", 350～500μ;Signal "1", 30～100μ;Signal "2", 0 ~ 30μ;Signal "3", -10 ~ +10μ✿ Electrical zero adjustable range:Not less than 100μ, and ±5μ fine adjustment✿ Repeat error:No more than 1μ✿ (Grid) voltage adjustment error:No more than 3μ✿ Instability:Time drift is no more than 10μ/4 hours; temperature drift is no more than 10μ/ 10℃ 8.2 ZD41B Short Cylindrical Roller Sorting MachineThis machine is composed of high-precision micrometer (differential transformer), combined with transistor circuit to form measurement and logic control device to complete the task of automatically sorting short cylindrical bearing rollers. • Main technical indicators◆ Measurement range:length is no more than 15mm5 to 15 mm in diameter◆ Accuracy:1μ, 2μ, 3μIf the magnification and radial grouping potentiometer are re-tuned, any grouping in the range of 0.5 to 5μ can be obtained.◆ Number of groups:10 groups.◆ Speed:28/min to 65/min,can be adjusted arbitrarily • Working principleThe measurement and classification of the radial dimensions of the roller are automated. The roller to be tested is manually placed in a disc-shaped hopper, passed through the vibrating roller to the feeding position along the pipe, and then pushed into the measuring portion by the reciprocating push rod for radial measurement. When different sizes of rollers enter the measurement site for measurement, the differential transformer guide core is displaced in the coil, so that the differential transformer outputs an alternating current signal proportional to the change in the size of the roller, and tiny electrical signal is amplified, rectified, and then amplified by the DC amplifier, so that the corresponding trigger drives the relay and the electromagnet to open the storage valve of the sorting group, so that the measured rollers of different diameters are placed in different sorting bins for automated measurement and sorting. Here we mainly introduce the radial dimension measurement part, namely the differential transformer and its secondary circuit. The measuring part of the roller consists of a differential transformer, a 4KHz oscillator, an attenuator, a low-frequency AC amplifier, a phase-sensitive rectification, a DC amplifier, a regulated power supply, etc. ① Micrometer (differential transformer): The differential transformer is used to convert the diameter of the roller into a change in the amount of electricity. The primary coil is excited by a rectangular wave with a frequency of 4 kHz and an amplitude of 2 to 3 volts. Thus, the voltages of u2 and u3 are induced in the secondary coil. The different names of the secondary coils are connected as a common point ground, and the other ends serve as a differential output and form a bridge balance loop with the resistors R1, R2 and the potentiometer VR.  When the iron core is at the center position of the two secondary coils, since the magnetic resistance of the two coils is equal, the bridge is in a balanced state, and the differential transformer output E2=0 (u2=u3). In a static state, due to the self-weight of the iron core and the guide rod, the iron core is located at the lowermost end of the secondary coil, thus outputting a negative polarity voltage; when the roller is measured, the guide rod is displaced upward, and the iron core is also displaced upward in the differential coil. The output voltage varies with the displacement. When the displacement exceeds the center position, the differential transformer outputs a positive voltage. ② Oscillator: A high-frequency triode is used as a capacitive voltage divider oscillator with an oscillation frequency of 4KHz. This circuit feature avoids the difficulty of inductive oscillator winding. The intermediate transformer is used to couple the output, and then through the first-stage voltage amplification, the two pairs of Zener diodes are used to limit the clipping to form a rectangular wave with constant amplitude (2~3V), one way is for the primary excitation of the differential transformer and the other is for the phase-sensitive rectification comparison voltage. ③ AC amplifier: three-stage amplification circuit and transformer-coupled output. In order to keep the amplifier gain stable, 20dB negative feedback is introduced between the first and second stage, and the total gain is 75~80dB. ④ Phase-sensitive rectifier circuit: diode half-wave phase-sensitive rectification is used, the comparison voltage amplitude is high, and both diodes are turned on in the positive half cycle. The signal voltage is small, the positive voltage is output in the same phase with the comparison voltage, and the negative voltage is output in the opposite phase with the comparison voltage. ⑤ DC differential amplifier: The DC voltage output from the phase-sensitive rectifier circuit is further amplified and the polarity is converted. When inputting ±50mV, the differential output is 4~12V. 8.3 Discussion of Differential Transformer Application(1) The above example uses the two directions of the differential transformer and is determined for the special purpose of roller sorting. When measuring with a roller of nominal size, the differential transformer core is just adjusted to the center position, the positive tolerance roller produces a positive displacement, and the positive voltage is output; the negative tolerance roller produces a negative displacement and outputs a negative voltage. This makes full use of the linear range of the differential transformer. For different applications, especially for small-range, high-precision measurements, there is no need to distinguish the direction of the displacement. It is also possible to use only the displacement of the differential transformer in one direction, and the corresponding circuit can be simplified. (2) This product was a product of the 1970s, so a transistor discrete component circuit was used. Today's electronic technology and the component levels are no longer the same. AC amplifiers and DC amplifiers can be used with operational amplifiers, and performance is much better than discrete component circuits. The basic principles of the circuit and the various functional parts are still applicable and can be designed accordingly. (3) Nowadays, the application of single-chip microcomputers can completely replace the various logic circuits in the past. In the case of a single-chip microcomputer, the entire circuit design may vary greatly. For example, the oscillation source can be digitized (crystal oscillator frequency division may be directly generated by a single-chip microcomputer), and the measurement result is digitized (via A/D conversion), and a large number of analog comparators, triggers can be replaced by program judgment methods.  Furthermore, with the precise timing and synchronization function of the single-chip microcomputer, A/D conversion can be directly performed on the AC signal sampling, and the phase-sensitive rectifier circuit can be omitted. After the measurement results are digitized, data transmission can be used instead of analog transmission, thus precision will not be lost, interference will not exist and transmission distance will be long. Ⅸ FAQ1. Why does LVDT use high voltage?It is a type of electrical transformer used for measuring linear displacement.The linear variable differential transformer has three solenoidal coils placed end-to-end around a tube. The center coil is the primary, and the two outer coils are the top and bottom secondaries. A cylindrical ferromagnetic core, attached to the object whose position is to be measured, slides along the axis of the tube. An AC current drives the primary and causes a voltage to be induced in each secondary proportional to the length of the core linking to the secondary.Cutaway view of an LVDT. Current is driven through the primary coil at A, causing an induction current to be generated through the secondary coils at B. When the core is displaced toward the top, the voltage in the top secondary coil increases as the voltage in the bottom decreases. The resulting output voltage increases from zero. This voltage is in phase with the primary voltage. When the core moves in the other direction, the output voltage also increases from zero, but its phase is opposite to that of the primary. The phase of the output voltage determines the direction of the displacement (up or down) and amplitude indicates the amount of displacement.  2. What are the advantages of using an LVDT?• Very reliable: Long sensor lifespan due to near frictionless operation of most models.• Very high resolution: Because of the near-frictionless movement they provide virtually infinite resolution. Even the smallest changes can be detected.• Damage resistant: In some models, both ends of the tube are open, preventing sensor damage if the test article pushes the rod farther than expected (except for collision with the tube itself).• Null point stability: The zero or null point of the sensor is extremely repeatable due to the construction of the sensor itself.• Wide range of operating temperatures: There are LVDT models available that can withstand cryogenic temperatures (-200℃/ -328℉) as well as high temperatures (650℃/ 1200℉)• Low hysteresis/ high positional accuracy and repeatability• Absolute reading output device: As opposed to an incremental output device, the reading from an LVDT will be the same before and after its power is cycled (assuming that the object under test did not move).  3.What are the disadvantages of using an LVDT?• Limited measurement distance: Even the largest LVDTs are limited to less than 1m (~27'') measurement ranges.• Can be affected by magnetic fields (models with shielding are common as a result).• AC models require a precise AC excitation from an LVDT signal conditioner.• DC LVDT models have an inferior shock, vibration and temperature specifications compared to AC LVDT models. 4. How do I interface an LVDT output with PLC?The output is voltage so you will need an analog input card which can take in a voltage input and then inside the PLC you will scale what that voltage corresponds to. For eg 10 V could mean 10 mm or 10 degrees etc. If the output is current them you would need an analog IP card which accepts current. Most common current used is 4–20 mA. 5. What are the applications of the Bourdon tube and the LVDT method for pressure measurement?A bourdon tube is a curved, hollow, closed end tube which can be pressurized. The pressure will attempt to straighten out the tube as it is increased. The amount of movement is typically very small but can be mechanically amplified. The translation of the end of the tube can be a linear indication of the pressure applied to the other end.Pressure gauges have used this technique for over a century and a half to indicate pressure manually on a dial gauge with a linkage that moves a dial pointer.To make electronic readouts of pressure to remote dials or to computers, a linear movement to electrical voltage is needed. An LVDT satisfies this need. An LVDT is a variable transformer consisting of a movable magnetic core sliding inside a tube with a primary and secondary winding. As the core is displaced the coupling between windings is varied linearly. If a small AC voltage is applied to the primary then the amplitude of the secondary output can be measuered in amplitude to indicate proportional to the pressure.So this makes a hybrid sensor or transducer, pressure to displacement connected to a displacement to variable voltage resulting in a pressure to variable voltage device.Technically this is an older way of converting pressure to volts… and is subject to hysteresis or mechanical backlash. Most modern P-V transducers use strain gauge bridge followed by an instrumentation amplifier to have fewer moving parts and less hysteresis. 6. Discuss various applications where LVDT’s can be used?They can be used in any application where a highly accurate measurement of linear displacement or position is needed. This includes precision gaging systems for measurement and metrology, feedback transducers for precision servomechanisms, torque, force and moment transducers, materials testing equipment (tensile testers, rheometers, fatigue testers, etc.). 7.What is the accuracy of a LVDT and an inductance transducer in a displacement measurement?Accuracy for both devices depends on the way they are designed, made and used, and the materials from which they are made. As well as calibration.However, neither on their own give “readings”. They need conditioning and interface circuitry. (I do recognise that the “inductance transducer” is a two-word item, and that the second word - transducer - implys that at least some form of signal conditioning exists therein.)That cicuitry is at least as important as the device itself.To give typical values for accuracy, is difficult without more specifics, though it is usual to be able to achieve several significant figures of accuracy out of each. 8. What is LVDT in measurement?A Linear Variable Differential Transducer is a sensor based on the idea of transformers. As its name shows it's a Linear sensor used in measuring displacements.  It has an iron core that moves up and down in the gap separating the primary and secondary coils. So the coils are not physically connected. The secondary coils are connected in opposition such that the output voltage is the difference between the voltages induced in the first and second secondary coils. The components whose Displacement is required to be measured should be connected to the core, so the input to the sensor is the displacement، the output would be the differential voltage output and after some manipulation using the sensitivity and sensor resolution, the displacement can be obtained. 9. How does a DC LVDT work?An oscillator/demodulator circuit built into the displacement transducer supplies the excitation and converts the return signal to a dc voltage. ... As the transducer contains internal signal conditioning electronics, there is no need for external signal conditioning. 10. Is LVDT an active transducer?The active transducer is also called a self-generating type transducer. ... Example of an active transducer is the bourdon tube. An example of a passive transducer is LVDT (linear variable differential transformer). It generates electric current or voltage directly in response to environmental stimulation.

Inflammation is a good thing when it's fighting off infection, but too much can lead to autoimmune diseases or cancer. In efforts to dampen inflammation, scientists have long been interested in CC chemokine receptor 2 (CCR2)—a protein that sits on the surface of immune cells like an antenna, sensing and transmitting inflammatory signals that spur cell movement toward sites of inflammation. Researchers at the Skaggs School of Pharmacy and Pharmaceutical Sciences at University of California San Diego have now determined the 3D structure of CCR2 simultaneously bound to two inhibitors. Understanding how these molecules fit together may better enable pharmaceutical companies to develop anti-inflammatory drugs that bind and inhibit CCR2 in a similar manner.CCR2 and associated signaling molecules are known to play roles in a number of inflammatory and neurodegenerative diseases, including multiple sclerosis, asthma, diabetic nephropathy and cancer. Many drug companies have attempted to develop drugs that target CCR2, but none have yet made it to market."So far drugs that target CCR2 have consistently failed in clinical trials," said Tracy Handel, PhD, professor in the Skaggs School of Pharmacy. "One of the biggest challenges is that, to work therapeutically, CCR2 needs to be turned 'off' and stay off completely, all of the time. We can't afford ups and downs in its activity. To be effective, any small molecule drug that inhibits CCR2 would have to bind the receptor tightly and stay there. And that's difficult to do."Handel led the study with Irina Kufareva, PhD, project scientist at Skaggs School of Pharmacy, and Laura Heitman, PhD, of Leiden University. The study's first author is Yi Zheng, PhD, postdoctoral researcher also at Skaggs School of Pharmacy.CCR2 spans the membrane of immune cells. Part of the receptor sticks outside the cell and part sticks inside. Inflammatory molecules called chemokines bind the external part of CCR2 and the receptor carries that signal to the inside of the cell. Inside the cell, CCR2 changes shape and binds other communication molecules, such as G proteins, triggering a cascade of activity. As a result, the immune cells move, following chemokine trails that lead them to places in the body where help is needed.In this study, the researchers used a technique known as X-ray crystallography to determine the 3D structure of CCR2 with two molecules bound to it simultaneously—one at each end.That's a huge accomplishment because, Kufareva said, "Receptors that cross the cell membrane are notoriously hard to crystalize. To promote crystallization, we needed to alter the amino acid sequence of CCR2 to make the receptor molecules assemble in an orderly fashion. Otherwise, when taken out of the cell membrane, they tend to randomly clump together. "Handel, Kufareva and team also discovered that the two small molecules binding CCR2 turn the receptor "off" by different but mutually reinforcing mechanisms. One of the small molecules binds the outside face of the receptor and blocks binding of the natural chemokines that normally turn the receptor "on." The other small molecule binds the face of the receptor inside the cell, where the G protein normally binds, preventing inflammatory signal transmission. According to Handel, the latter binding site has never been seen before.