Method and Apparatus for Nondestructive Testing of a Gas Discharge Tube

Abstract

A method and apparatus for nondestructive testing of a gas discharge tube (GDT) comprising: electrically connecting a first terminal of the GDT to a first port of a vector network analyzer (VNA); electrically connecting a second terminal of the GDT to a second port of the VNA; measuring S parameters with the VNA; determining GDT capacitance and insertion loss based on the measured S parameters; comparing the determined capacitance and insertion loss of the GDT with a threshold value to determine if the GDT is functional.

Claims

1. A method for nondestructive testing of a gas discharge tube (GDT) comprising the following steps: electrically connecting a first terminal of the GDT to a first port of a vector network analyzer (VNA); electrically connecting a second terminal of the GDT to a second port of the VNA; measuring S parameters with the VNA; determining GDT capacitance based on the measured S parameters; comparing the determined capacitance of the GDT with a threshold value to determine if the GDT is functional.

2. The method of claim 1, wherein no electrical performance characteristics of the GDT are known before the testing of the GDT, and wherein the threshold value is determined by calculating the average measured capacitance of a plurality of newly manufactured GDTs.

3. The method of claim 1, wherein the GDT is a used GDT.

4. The method of claim 2, wherein the GDT is a new GDT.

5. The method of claim 2, wherein the capacitance of the GDT is determined at the first and second ports by solving the following equations respectively:
C.sub.1=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.11))/((1REAL(S.sub.11)).sup.2+IMAG(S.sub.11).sup.2))) and
C.sub.2=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.22))/((1REAL(S.sub.22)).sup.2+IMAG(S.sub.22).sup.2))).

6. The method of claim 1, wherein the threshold value is a multiple factor of the GDT's known breakdown voltage.

7. The method of claim 1, wherein the GDT is a transient protection device (GDT) designed to protect devices from electricity surges.

8. The method of claim 1, further comprising measuring the insertion loss (IL) at the first and second terminals of the GDT with the VNA according to the following equations: IL.sub.1=20 log.sub.10|S.sub.21| and IL.sub.2=20 log.sub.10|S.sub.12| to further determine GDT functionality.

9. The method of claim 5, wherein the threshold value is established by subjecting a GDT to a high voltage pulser injection test and measuring an after-test capacitance, and then selecting the pass and fail threshold value of the GDT to be a capacitance C having a value that is at least 5-10% different from the value of the determined capacitance.

10. The method of claim 5, wherein the threshold value is established by subjecting a GDT to a high voltage pulser injection test, measuring an after-test capacitance, and determining a relationship between a Townsend breakdown voltage V.sub.bT and the capacitance C according to the following: $V_{\mathrm{bT}}=\frac{\frac{.Math..Math.A}{C}*E_I}{{}_e*\ln \left(\frac{.Math..Math.A}{C.Math..Math.{}_e}\right)},$ where E.sub.I is an unknown ignition energy (in joules), and .sub.e is an unknown mean free path (in meters), is the electric permittivity of an unknown gas within the GDT, and A is an unknown area of electrodes within the GDT.

11. A gas discharge tube (GDT) tester comprising: a vector network analyzer (VNA) having a first port and a second port; a processor operatively coupled to the VNA; a test fixture configured to allow a first terminal of a test GDT to be electrically connected to the first port and a second terminal of the test GDT to be electrically connected to the second port; and wherein the VNA is configured to measure the S.sub.11 and S.sub.22 parameters of the test GDT, and the processor is configured to calculate the capacitances of the test GDT at the first and second ports based on the measured S parameters, and wherein the processor is further configured to compare the calculated capacitances with a threshold value to determine if the test GDT is functional.

12. The GDT tester of claim 11, wherein the processor is configured to calculate the capacitances of the test GDT at the first and second ports by respectively solving the following equations:
C.sub.1=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.11))/((1REAL(S.sub.11)).sup.2+IMAG(S.sub.11).sup.2))) and
C.sub.2=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.22))/((1REAL(S.sub.22)).sup.2+IMAG(S.sub.22).sup.2))).

13. A method for nondestructively testing a first gas discharge tube (GDT) comprising the following steps: a. electrically connecting a first terminal of the first GDT to a first port of a vector network analyzer (VNA); b. electrically connecting a second terminal of the first GDT to a second port of the VNA; c. measuring S parameters with the VNA to obtain frequency-dependent reflection and transmission properties of the first GDT; d. determining first GDT capacitance at the first and second ports based on the measured S parameters related to the reflection properties; e. determining first GDT insertion loss at the first and second ports based on the measured S parameters related to the transmission properties; and f. comparing the determined capacitance and insertion loss of the first GDT with threshold capacitance and insertion loss values respectively to determine if the first GDT is functional.

14. The method of claim 13, wherein the capacitance threshold value is determined by: determining the capacitance of a plurality of new GDTs according to steps (a-d); and averaging the determined capacitances of the plurality of new GDTs, wherein the average determined capacitance is the threshold capacitance.

15. The method of claim 14, wherein step (f) further comprises calculating a correlation coefficient between the determined capacitance of the first GDT and the average new GDT capacitance.

16. The method of claim 15, wherein the insertion loss threshold value is determined by: determining the insertion loss of a plurality of new GDTs according to steps (a-c) and (d); and averaging the determined insertion losses of the plurality of new GDTs, wherein the average determined insertion loss is the threshold insertion loss.

17. The method of claim 16, wherein step (f) further comprises calculating a correlation coefficient between the determined insertion loss of the first GDT and the average new GDT insertion loss.

18. The method of claim 17, wherein the first GDT is a used GDT with unknown internal characteristics.

19. The method of claim 17, further comprising the step of subjecting one of the plurality of new GDTs to high voltage pulser injection tests to determine the Townsend breakdown voltage V.sub.bT of the new GDT.

20. The method of claim 19, wherein step (f) further comprises comparing the first GDT capacitance at the first and second ports to the Townsend breakdown voltage V.sub.br according to the following relationship: $V_{\mathrm{bT}}=\frac{\frac{.Math..Math.A}{C}*E_I}{{}_e*\ln \left(\frac{.Math..Math.A}{C.Math..Math.{}_e}\right)},$ where C is the measured capacitance of the first GDT at either the first or second ports, E.sub.I is an unknown ignition energy (in joules), and A, is an unknown mean free path (in meters), is the electric permittivity of an unknown gas within the first GDT, and A is an unknown area of electrodes within the first GDT.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Throughout the several views, like elements are referenced using like references. The elements in the figures are not drawn to scale and some dimensions are exaggerated for clarity.

[0008] FIG. 1 is a flowchart of a method for nondestructive testing of a gas discharge tube.

[0009] FIG. 2 is an illustration of a sealed gas discharge tube.

[0010] FIG. 3 is a representation of a two-port vector network analyzer connected to a gas discharge tube.

[0011] FIG. 4 is an illustration of a gas discharge tube tester.

[0012] FIG. 5A is a graph of example calculated capacitances of several different gas discharge tubes at several different frequencies.

[0013] FIG. 5B is a chart of capacitance correlation coefficients from 4-30 MHz for several different gas discharge tubes.

[0014] FIG. 6 is a graph of the determined transmission loss of several different gas discharge tubes at different frequencies.

[0015] FIG. 7 is a chart of insertion loss correlation coefficients from 2-30 MHz for several different gas discharge tubes.

[0016] FIG. 8 is a graph of determined capacitance values with respect to various frequencies of a single gas discharge tube after several high voltage pulser injection tests.

DETAILED DESCRIPTION OF EMBODIMENTS

[0017] The disclosed methods and systems below may be described generally, as well as in terms of specific examples and/or specific embodiments. For instances where references are made to detailed examples and/or embodiments, it should be appreciated that any of the underlying principles described are not to be limited to a single embodiment, but may be expanded for use with any of the other methods and systems described herein as will be understood by one of ordinary skill in the art unless otherwise stated specifically.

[0018] FIG. 1 is a flowchart of an embodiment of a method 10 for nondestructive testing of a gas discharge tube (GDT). The GDT may be any make/model of GDT with known or unknown characteristics. The GDT may be new or used. GDTs are often used as terminal protection devices (sometimes referred to as transient protection devices) designed to protect electronic devices from electricity surges. Method 10 comprises, consists of, or consists essentially of the following steps. The first step 10.sub.a provides for electrically connecting a first terminal of the GDT to a first port of a vector network analyzer (VNA). Any VNA having at least two ports and capable of measuring S parameters may be used with method 10. The next step 10.sub.b provides for electrically connecting a second terminal of the GDT to a second port of the VNA. The next step 10.sub.c provides for measuring S parameters with the VNA. The next step 10.sub.d provides for determining GDT capacitance and insertion loss based on the measured S parameters. The next step 10.sub.e provides for comparing the determined capacitance and insertion loss of the GDT with a threshold value to determine if the GDT is functional.

[0019] FIG. 2 is an illustration of an example of a test GDT 12 having a first terminal 14 and a second terminal 16 that may be tested by method 10. In many scenarios, no electrical performance characteristics of the test GDT 12 are known before the testing of the test GDT 12. The threshold value may be determined by calculating the average measured capacitance of a plurality of newly manufactured GDTs. The physics of a sealed GDT, such as the one depicted in FIG. 2, are similar to a capacitor having two internal parallel plate electrodes separated by a gas-filled gap. Thus the mathematical model of the parallel-plate capacitance equation may be used to describe the capacitance of a GDT.

[00001]$\begin{array}{cc}C=\frac{A}{d}& \left(1\right)\end{array}$

Where C is the frequency-dependent capacitance, is the electric permittivity of the gas material, A is the area of the electrodes, and d is the distance between the two electrodes. Equation (1) may be rewritten to solve for d as follows:

[00002]$\begin{array}{cc}d=\frac{A}{C}& \left(2\right)\end{array}$

[0020] FIG. 3 is a representation of a two-port VNA 18 connected to the test GDT 12. The VNA 18 has a first port 20 and a second port 22 electrically connected to the first and second terminals of the test GDT 12 respectively. The objective of using the parallel-plate capacitor model for the GDT is to obtain the device impedance and insertion loss as a function of frequency. The frequency-dependent reflection and transmission properties of the GDT can be obtained using a VNA two-port S-Parameter measurement approach in a series configuration such as is shown in FIG. 3. The two-port S-parameters have the following generic descriptions: S.sub.11 is the input port voltage reflection coefficient; S.sub.12 is the reverse voltage gain; S.sub.21 is the forward voltage gain; and S.sub.22 is the output port voltage reflection coefficient.

[0021] The impedance in terms of capacitance may be determined from the reflection property. In some cases, the capacitance of a given GDT may be disclosed by a manufacturer. The insertion loss may be determined from the GDT transmission property. Manufacturers of GDTs do not provide insertion loss specifications. With limited GDT electrical performance specifications from the manufacturer and no design material and dimension information (e.g., gas mixture and pressure, gap geometry, gap distance, and electrode alloy make-up) available on a given GDT, a statistical an embodiment of method 10 uses a statistical approach to address the pass/fail criteria of the given GDT using the VNA 2-port S-Parameters measurement techniques. The assumption for the pass/fail criteria is that if no physical changes were made to the GDT internal and external structures and materials over time, the capacitance and insertion loss function of frequencies should be relatively stable like a new unit.

[0022] The procedures below summarize a quantitative research statistical approach for GDT capacitance and insertion loss measurements to determine the pass/fail criteria. Capacitance may be calculated from the S.sub.11 and S.sub.22 measurements as follows:

Capacitance from S Parameters

[00003]$\begin{array}{cc}\frac{-1}{j.Math..Math.2.Math..Math..Math.\mathrm{fC}}=Z_0.Math.\frac{1+\left(S_{11}.Math..Math.\mathrm{or}.Math..Math.S_{22}\right)}{1-\left(S_{11}.Math..Math.\mathrm{or}.Math..Math.S_{22}\right)}& \left(3\right)\end{array}$

Where

[0023] f=Frequnecy (Hz)

C=Capacitance

[0024] Z.sub.0=Characteristic impedance 50 ohms
Equation (3) may be rewritten as follows to solve for C.sub.1 at the first port 20:

C.sub.1=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.11))/((1REAL(S.sub.11)).sup.2+IMAG(S.sub.11).sup.2)))(4)

Equation (4) may also be expressed as follows:

[00004]$C_1=\frac{-1}{2**f*\left|\frac{50*2*\mathrm{IMAG}\left(S_{11}\right)}{{\left(1-\mathrm{REAL}\left(S_{11}\right)\right)}^2+{\mathrm{IMAG}\left(S_{11}\right)}^2}\right|}$

Equation (3) may be rewritten as follows to solve for C.sub.2 at the second port 22:

C.sub.2=1/(2*3.14159*f*ABS((50*2*IMAG(S.sub.22))/((1REAL(S.sub.22)).sup.2+IMAG(S.sub.22).sup.2)))(5)

Equation (5) may also be expressed as follows:

[00005]$C_2=\frac{-1}{2**f*\left|\frac{50*2*\mathrm{IMAG}\left(S_{22}\right)}{{\left(1-\mathrm{REAL}\left(S_{22}\right)\right)}^2+{\mathrm{IMAG}\left(S_{22}\right)}^2}\right|}$

[0025] Insertion loss may be obtained from the S.sub.21 and S.sub.12 measurements.

Insertion Loss from S Parameters
The insertion loss (IL.sub.1) at the first port 20 may be calculated from the S.sub.21 measurement according to the following equation:

IL.sub.1=20 log.sub.10|S.sub.21|dB(6)

The insertion loss (IL.sub.2) at the second port 22 may be calculated from the S.sub.12 measurement according to the following equation:

IL.sub.2=20 log.sub.10|S.sub.12|dB(7)

[0026] FIG. 4 is an illustration of a GDT tester 24 that comprises the VNA 18, a processor 26, and a test fixture 28. The processor 26 is operatively coupled to the VNA 18 such that when the VNA 18 measures the S.sub.11, S.sub.21, S.sub.12 and S.sub.22 parameters of the test GDT 12, the processor 26 is configured to calculate the capacitances and/or the insertion loss of the test GDT 12 at the first and second ports 20 and 22 respectively based on the measured S parameters. The processor 26 may also be used to compare the calculated capacitances and insertion losses with threshold values to determine if the test GDT 12 is functional. The test fixture 28 serves to hold the test GDT 12 in position such that the first terminal 14 is electrically connected to the first port 20 and the second terminal 16 is electrically connected to the second port 22. The test fixture 28 may be made of a base ground plate 30 with two brackets 32 with measurement clips 34 (shown in FIG. 4 as being connected to the first and second terminals 14 and 16).

[0027] FIG. 5A is a graph of example calculated capacitances of several different GDTs at several different frequencies. One way to calculate the capacitance and insertion loss threshold values is to calculate an average capacitance and an average insertion loss from a plurality of new GDTs. These averages may be used as the performance specification. For capacitance, a correlation analysis may then be performed of the test GDT 12's S.sub.11 and S.sub.22 trace data against the average capacitance. The correlation coefficient from the correlation analysis provides a pass/fail metric to determine the functionality of new and previously installed GDTs. FIG. 5B is a chart of capacitance correlation coefficients and GDT condition from 4-30 MHz from the S.sub.ii measurement for several different GDTs. All of the measured GDTs whose measurement data is displayed in FIG. 5B had a capacitance correlation coefficient of greater than 0.995 and were thus deemed to be functional GDTs.

[0028] FIG. 6 is a graph of the determined transmission loss of several different GDTs at different frequencies from the S.sub.21 and S.sub.it measurements. For insertion loss, a correlation analysis may then be performed of any given GDT's S.sub.21 and S.sub.12 trace data against the average insertion loss. FIG. 7 is a chart of insertion loss correlation coefficients and GDT condition from 2-30 MHz from the S.sub.21 and S.sub.12 trace measurements for several different GDTs. All of the measured GDTs whose measurement data is displayed in FIGS. 6 and 7 had an insertion loss correlation coefficient of greater than 0.999998 and were thus deemed to be functional GDTs.

[0029] The inventors of the invention claimed herein have discovered a relationship between a GDT's determined capacitance and its breakdown voltage. Plasma ignition occurs at the Townsend breakdown voltage, which may be measured and expressed as follows:

[00006]$\begin{array}{cc}{V}_{\mathrm{bT}}=\frac{d*E_I}{{}_e*\ln \left(\frac{d}{{}_e}\right)}& \left(8\right)\end{array}$

Where V.sub.bT is the Townsend breakdown voltage (in volts), d is the distance (in meters) from the cathode to the anode, E.sub.I is the ignition energy (in joules), and .sub.e is the mean free path (in meters). Next, one may substitute the expression for d from equation (2) into equation (8) to yield:

[00007]$\begin{array}{cc}{V}_{\mathrm{bT}}=\frac{\frac{A}{C}*E_I}{{}_e*\ln \left(\frac{A}{C.Math..Math.{}_e}\right)}& \left(9\right)\end{array}$

[0030] FIG. 8 is a graph of determined capacitance values with respect to various frequencies of a single GDT (identified as GDT 9 in FIG. 8) based on S.sub.11 measurements with a VNA after several high voltage pulser injection tests. A GDT's breakdown voltage may be determined experimentally by subjecting a given GDT to high voltage pulser injection tests. For example, a high voltage injection test may be associated with a predetermined high voltage and high current test waveform that is injected into the primary side of a device to determine how the device behaves at a particular level of current. The primary function of a high voltage injection test is to supply sufficient current to simulate the characteristic of a transient electrical surge waveform for the GDT under test. Starting at 50% of the rated breakdown voltage, the voltage on the high voltage power supply may be slowly increased until a current draw of 1 mA is observed on the power supply. Once this occurs, the voltage reading on the power supply may be recorded as the DC breakdown voltage. The threshold value used in method 10 may be a multiple factor of the breakdown voltage specification as provided by a manufacturer, or it may be established by subjecting a sacrificial GDT to a high voltage pulser injection test and measuring the capacitance afterward, and then selecting the pass and fail threshold value of the test GDT to be a capacitance C that results in 5-10% percentage capacitance changes from the capacitance of a GDT that is known to be functional. An embodiment of method 10 establishes a GDT capacitance relationship to the Townsend breakdown voltage equation as shown in equation 12. This equation relates the capacitance changes due to different high voltage injection hits above the GDT manufacturer breakdown voltage specification.

[0031] From the above description of the method 10 for nondestructive testing of a gas discharge tube, it is manifest that various techniques may be used for implementing the concepts of method 10 without departing from the scope of the claims. The described embodiments are to be considered in all respects as illustrative and not restrictive. The method/apparatus disclosed herein may be practiced in the absence of any element that is not specifically claimed and/or disclosed herein. It should also be understood that method 10 is not limited to the particular embodiments described herein, but is capable of many embodiments without departing from the scope of the claims.