Design and manufacture of a 12.5 kV high pot device for the sanitary condom tester project V5.0
In condom manufacturing factories, it is necessary to test condoms for the absence of holes after initial production. This test is carried out with an electronic testing device or ET. The basis of this device is to create a high-voltage circuit. If the condom has a hole, a short circuit occurs in the circuit and the device rejects the condom.
This 12.5 kV high-voltage device was designed and built for the research and development phase of the project to develop and manufacture condom testers.
This high-voltage device is able to detect holes on condoms in three areas:
1-Holes in the first area (the hole is in the upper third of the condom)
2-Holes in the second area (the hole is in the middle third of the condom)
3-Holes in the third area (the hole is in the bottom third of the condom)
In this version of the high voltage system design, it was decided to build a separate high voltage system for each area on the mandrel. Since we perform high voltage tests in two stages in the ET device and three areas with different voltages are tested in each stage, 6 high pot packages were produced in this project.
Below you can see photos of this device in the research and development phase.
The figure below shows the prototype of this high-voltage driver in the research and development phase.
In this high-voltage system, high-speed optocouplers are used to protect the pulses caused by the detection of holes in the condom.
It should be noted that auto-ignition coils are used as the source of spark generation in this high-voltage system and this circuit board is used as an ignition coil driver.
In the video below you can see an example of the spark generated by this high voltage system.