Systems that supply power to a load, test circuitry for testing the voltage supply to a load, and tangible non-transient computer-readable media.

Abstract

This invention relates to an input / output (I / O) module power supply with online load testing capability. Embodiments of this disclosure include an input / output (I / O) power supply module coupled to a load. The I / O power supply module may include a test circuit system coupled to a voltage supply to the I / O power supply module. The test circuit system can perform online load current testing to verify the performance of the I / O power supply module. For this purpose, the test circuit system may include a current measurement circuit coupled to a switch. The current measurement circuit can receive current via the switch when closed to determine whether the output current generated by the voltage supply is equal to the rated output current.

Description

Technical Field

[0001] This disclosure generally relates to systems and methods for supplying power to input / output (I / O) modules within industrial automation systems. More specifically, embodiments of this disclosure relate to supplying power from the power supply of concurrently operating I / O modules within an industrial automation system to a load. Background Technology

[0002] This section is intended to introduce the reader to various aspects of the technology that may be related to the aspects described below and / or claimed in this disclosure. This discussion is intended to help provide the reader with background information to facilitate a better understanding of the various aspects of this disclosure. Therefore, it should be understood that these statements are to be interpreted in this context and not as an admission of prior art.

[0003] Industrial automation systems can include automated control and monitoring systems. These systems can monitor conditions and / or receive sensor data from a variety of devices, such as valves, electric motors, various types of sensors, and other suitable monitoring devices. Furthermore, one or more components of these automated control and monitoring systems, such as programming terminals, automation controllers, input / output (IO) modules, communication networks, and human-machine interface (HMI) terminals, can use the status and / or collected information to provide alerts to operators to change or adjust the operation of one or more components of the industrial automation system (e.g., adjusting the operation of one or more actuators) to manage the industrial automation system.

[0004] Automated control and monitoring systems can modify how loads are operated based on monitored conditions or sensed data. To do this, the system can alter control signals supplied to networked devices, controlling whether the power supply delivers power to downstream loads. For example, a power-enabled I / O module (e.g., an I / O power processing module) can supply power to one or more downstream coupled loads. Over time, the physical materials forming the I / O power module may degrade, and components may malfunction. These types of problems that may arise from the I / O power module can cause its current output to decrease or diminish, resulting in a current output that no longer meets the expected current rating for the I / O power module.

[0005] To test for unexpected current output, the load can be energized via the I / O power module to verify that the current level output by the I / O module meets the load's current rating. Keeping this in mind, it should be noted that in some cases, it may not be desirable to energize the load for routine testing of the I / O power module in industrial automation systems where equipment operates continuously to perform manufacturing and other automated tasks. Therefore, improved systems and methods for load current testing of devices within industrial automation systems may be desired. Summary of the Invention

[0006] The following provides an overview of some of the embodiments disclosed herein. It should be understood that these aspects are presented merely to provide the reader with a brief overview of these embodiments, and are not intended to limit the scope of this disclosure. In fact, this disclosure may cover various aspects that may not be stated below.

[0007] In one embodiment, the system may include: a voltage supply capable of supplying output current to a load; and a test circuit system coupled to the voltage supply. The test circuit system may include an additional voltage supply, a switch, and a current measurement circuit, the switch being capable of closing in response to a voltage signal from the additional voltage supply. The current measurement circuit may be coupled to the switch. The current measurement circuit may receive output current from the voltage supply when the switch is closed. Furthermore, the system may include a control system that receives an indication of the voltage across the current measurement circuit from a sensing circuit when the switch is closed, the control system determining the amount of current present in the output current based on a resistance value associated with the current measurement circuit and the voltage, and the control system performing operations based on the amount of current.

[0008] In another embodiment, the test circuit may include a voltage supply and a switch. The switch may close in response to receiving a voltage signal from the voltage supply. The test circuit may also include a timing circuit coupled to the voltage supply and a ground terminal. The timing circuit may limit the amount of time for which the voltage signal is provided to the switch. The test circuit may also include a current measurement circuit coupled to the switch. The current measurement circuit may receive an output current from an additional voltage supply during this amount of time when the switch is closed, and the additional voltage supply may provide power to a load.

[0009] In another embodiment, the tangible non-transitory computer-readable medium may store instructions executable by a processor of an electronic device, which, when executed by the processor, cause the processor to perform operations including receiving an instruction to verify the output current of a first input / output (I / O) power supply module coupled to a load. The operations may include closing a switch for a specified duration in response to the instruction to request and detecting the voltage across one or more resistors coupled between the switch and a ground terminal. The operations may include determining the amount of current present in the output current transmitted via one or more resistors based on the resistance value and voltage of the one or more resistors. Furthermore, the operations may include transmitting a notification in response to a difference between the amount of current and the rated output current exceeding a threshold amount. Attached Figure Description

[0010] These and other features, aspects, and advantages of the embodiments will be better understood when the following detailed description is read with reference to the accompanying drawings, in which the same characters denote the same parts throughout the drawings:

[0011] Figure 1 This is a perspective view of an example distributed processing system according to an implementation method;

[0012] Figure 2 According to the implementation method, it includes Figure 1 A block diagram of an example industrial automation system with a distributed processing system;

[0013] Figure 3 It is coupled to according to the implementation method to Figure 2 The load supplies power Figure 2 A circuit diagram of a pair of I / O power processing modules; and

[0014] Figure 4 According to the implementation method, without using Figure 2 Used to operate the control system for testing when the load is energized. Figure 2 The flowchart shows the process of load current in the corresponding IO power processing module. Detailed Implementation

[0015] When describing the elements of various embodiments of this disclosure, the articles “a,” “an,” “the,” and “described” are intended to indicate the presence of one or more elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that other elements besides those listed may be present. One or more specific embodiments of the present embodiments described herein will be described below. To provide a concise description of these embodiments, not all features of the actual implementation may be described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developer’s specific goals, such as compatibility with system-related constraints and business-related constraints, which may differ across implementations. Furthermore, it should be understood that while such development efforts may be complex and time-consuming, they remain routine tasks of design, fabrication, and manufacturing for those skilled in the art who benefit from this disclosure.

[0016] This disclosure generally relates to systems and methods for testing the load current output of an input / output (IO) power supply module without interrupting operations performed by a downstream coupled load or power received by a downstream coupled load from the IO power supply module.

[0017] Within industrial automation systems, certain components may be used intermittently, such as in response to the occurrence of an event or the detection of a condition. Therefore, these systems may remain dormant for extended periods (e.g., longer than a threshold time) before being used. For example, redundant power supplies, fire extinguishing agent systems, alarm systems, etc., may be used intermittently in industrial automation systems, rather than periodically or according to a schedule. Industrial automation systems including such devices can benefit from routine operational checks performed on the devices, such as periodically or according to a maintenance schedule, to verify their operational status. These operational checks may include powering the load or operating the device to verify its operation. Sometimes, verifying operation by powering the load may be impractical or undesirable. For example, fire extinguishing agent systems, such as those located in rooms or interiors with electrical equipment, can benefit from verification operations to ensure that the equipment performs according to its design specifications. However, performing verification operations on these types of systems may render the equipment unusable for future tasks. For example, after testing a fire extinguishing agent system, the system may disperse water, foam, air, sand, or other materials from its reserves, thereby extinguishing the fire extinguishing agent supply intended for future operations.

[0018] Another example of a system where performing physical verification operations may be difficult or undesirable involves testing redundant power supplies that simultaneously power the same load. For instance, an auxiliary power supply can back up the primary power supply, allowing both to simultaneously provide the same voltage to a shared load, such as an input / output (I / O) power module. Because both supplies continuously provide the same voltage to the shared load, the load can be seamlessly switched between the primary and auxiliary power supplies without any interruption. In practice, if the primary power supply becomes unavailable, the auxiliary power supply can replace it as the power source to the load. Furthermore, because both power supplies continuously and simultaneously provide the same voltage, it may be difficult or undesirable to take either power supply offline for verification testing. That is, when testing the feasibility of one of the two power supplies, the non-operating components of the power supply under test could become a source of unwanted current output to a load that operates on current, thereby jeopardizing the load's operation.

[0019] To address this problem, the systems and methods described herein relate to online verification testing that enables simultaneous power supply operation without interruption. To test the load current output of an I / O power supply module, a load can be coupled to two or more I / O power supply modules to provide redundant power supply. Each I / O power supply module can include test circuitry that enables the respective I / O power supply module to test its ability to output current from its corresponding voltage supply. The corresponding test circuitry system of the I / O power supply modules can perform online current load testing to verify the performance of the respective I / O power supply module while the load draws output current from another I / O power supply module. In this way, the load can continue to operate while one of the I / O power supply modules is being tested. To perform the current test, the test circuitry system of the I / O power module under test can include a switch that closes in response to receiving a pulse voltage signal. The switch can then connect the corresponding voltage supply of the I / O power module under test to one or more resistors coupled to the switch. The resistors can receive current via the voltage supply and the switch, thereby generating a voltage across one or more resistors. The control system can use voltage to calculate the current output by the corresponding voltage supply and determine whether the current generated by the voltage supply is equal to or substantially similar to the rated output current value for the voltage supply.

[0020] The test circuitry system described in this paper further improves the testing operation of the I / O power module because it utilizes a relatively small footprint when installed within the I / O power module. In fact, the circuitry described in this paper allows the power supply to be tested without turning its load on or off. By reducing the complexity of verifying the output from the power supply, it is less likely that a power supply operating in an undesirable manner will go undetected.

[0021] Through the introduction, Figure 1 This is a perspective view of an example distributed processing system 10. Distributed processing system 10 can be included within an industrial automation system to assist in performing operations, making control decisions, instructing the execution of operations in response to sensed data, implementing control loops, etc. Distributed processing system 10 can be a processing system that uses one or more computing devices or processors to perform one or more operations. Distributed processing system 10 includes a plurality of processing modules 12 (e.g., processing devices). Processing modules 12 can be interconnected with each other via a communication bus 14 (e.g., a shared communication bus). The communication bus 14 is located on one side of the processing modules 12 and, although not depicted, can be coupled to each of the processing modules 12 via a suitable backplane, input / output (I / O) circuitry, etc.

[0022] Each of the processing modules 12 can perform one or more operations that facilitate the operation of the industrial control system and can include any combination of hardware circuitry and / or software-based operations. For example, one of the processing modules 12 may include a processor and a memory that stores processor-readable instructions to cause the processor to perform one or more operations. Thus, the processing module 12 may include a tangible, non-transitory, computer-readable medium that stores instructions to cause the processing module 12 to perform operations on the industrial automation system.

[0023] Processing module 12 can perform control functions, power level functions, analysis engine functions, programmable logic controller (PLC) logic functions, etc. Control functions may include operations that generate output control signals in response to one or more inputs. Power level functions may include operations that cause modification of the distributed processing system 10 and / or components of the distributed processing system 10 in response to one or more inputs. In some cases, power level functions may operate to provide or permit electrical signals to loads or other components coupled to the processing module 12 performing the power level functions. Analysis engine functions may include operations that receive inputs and analyze them to determine conclusions. Input analysis may include historical trends of inputs over time, comparisons between input values, comparisons between input values ​​over time, etc. This analysis allows processing module 12 to diagnose or detect abnormal operations prior to faults or other abnormal operation-related events. Programmable logic controller (PLC) logic functions may include operations that generate outputs to be used in PLC operation. These outputs may include control signals and / or data signals referenced by the PLC to determine when to close or open certain electrical and / or mechanical components. Other suitable operations may be performed by one or more of processing modules 12.

[0024] The distributed processing system 10 may also include an input / output block (I / O block) 16. The I / O block 16 may include a termination point 18 in which input or output communication coupling can be secured. In the depicted example, the termination point 18 is a screw-in terminal in which input or output communication coupling is secured to a conductive terminal based on a screw-in coupling. Other types of terminals may be used, including plugs, loops, etc.

[0025] Each component of the distributed processing system 10 can be energized using an electrical signal from power supply 20. Power supply 20 may be coupled to a common power supply that supplies electrical signals to each of the other components via a power bus or another suitable electrical connection.

[0026] Some components of the distributed processing system 10 can be generalized to Figure 2 The block diagram shown. Now refer to... Figure 2An example industrial automation system 32 including a distributed processing system 10 is shown. The industrial automation system 32 may include sensing devices 34 coupled to the distributed processing system 10. The distributed processing system 10 may be coupled to a load 36. Therefore, the load 36 may receive analog electrical (e.g., voltage) signals via the input / output connections of the I / O block 16, receive digital signals via the input / output connections of the I / O block 16, or may receive both analog and digital signals. In some embodiments, the output from the distributed processing system 10 may adjust the operation of the I / O power processing modules 12C to change the operation of the load 36. For example, the distributed processing system 10 may determine to slow down the rotation of a motor (e.g., the load 36), and for this purpose, a request may be sent to at least one of the I / O power processing modules 12C to modify the electrical signals supplied to the motor as control operations (e.g., electrical signals received and output to the load 36 via the I / O block 16).

[0027] Although described as a motor, load 36 can be a variety of suitable components. Components of an industrial automation system can include various industrial equipment loads such as mixers, machine conveyors, tanks, skids, dedicated original equipment manufacturer (OEM) machines, fire extinguishing agent systems, etc. Components can also be associated with devices used by equipment such as scanners, meters, valves, flow meters, etc. In one embodiment, each aspect of the component can be controlled or operated by a single controller (e.g., a control system). In another embodiment, control and operation of each aspect of the component can be distributed via multiple controllers (e.g., control systems). Therefore, processing module 12 can control one or more aspects of load 36.

[0028] Components of the industrial automation system 32 (e.g., load 36, component load, processing components) can be used within a corresponding unit, area, or plant of the industrial automation system to perform various operations for that unit, area, or plant. In some embodiments, components can be communicatively coupled to each other, coupled to an industrial control system via communication bus 14, coupled to an industrial control system via processing module 12A, coupled to an industrial control system via processing module 12B, etc. Additionally, the industrial control system can also be communicatively coupled to one or more control systems that can monitor and / or control the operation of each corresponding unit, area, or plant.

[0029] Therefore, an industrial control system may include a computing device with communication capabilities, processing capabilities, etc. For example, an industrial control system may at least partially include a processing module 12 and / or may include a controller (e.g., a control system) such as a programmable logic controller (PLC), a programmable automation controller (PAC), or any other controller capable of monitoring, controlling, and operating industrial automation devices or components. An industrial control system may be integrated into any physical device (e.g., an industrial automation component) or may be implemented as a standalone computing device (e.g., a general-purpose computer) such as a desktop computer, laptop computer, tablet computer, mobile computing device, etc.

[0030] Industrial automation components can include user interfaces, industrial control systems, motor drives, motors, conveyors, and any other devices that enable an industrial automation system to produce or manufacture products or process certain materials. In addition to the types of industrial automation components mentioned above, industrial automation components can also include controllers, input / output (I / O) modules, motor control centers, motors, human-machine interfaces (HMIs), user interfaces, contactors, starters, sensors, drives, relays, protection devices, switching devices, compressors, network switches (e.g., Ethernet switches, modular management, fixed management, service routers, industrial, non-managed, etc.), etc. Industrial automation components can also relate to various industrial equipment such as mixers, machine conveyors, tanks, skids, and dedicated original equipment manufacturer (OEM) machines. Industrial automation components can also be associated with devices used in conjunction with equipment such as scanners, instruments, valves, flow meters, etc.

[0031] The sensing device 34 can sense parameters of the load 36 and / or parameters of the environmental conditions 42 of the load 36. The sensing device 34 can acquire sensing data and can output the sensing data to the processing module 12 via the I / O block 16. The sensing data can be in any suitable format and therefore can include one or more analog electrical signals, digital data signals, pulse-width modulated data signals, etc. Furthermore, in addition to or instead of wired communication, the I / O block 16 can be configured for wireless communication. Therefore, the sensing data can sometimes be transmitted to the distributed processing system 10 via wireless and / or radio frequency signals.

[0032] After the distributed processing system 10 receives sensing data from the sensing device 34, the corresponding processing module 12 within the distributed processing system 10 can analyze the sensing data to determine one or more outputs to be sent to the load 36. In some cases, this includes providing current from an IO power processing module 12C, which can be redundantly coupled to the load 36. The IO power processing modules 12C can simultaneously provide current to the load 36. Therefore, to test the output current from one of the IO power processing modules 12C, one of the IO power processing modules 12C can provide power to the load 36, while the other IO power processing modules 12C do not provide power to the load 36. Thus, the load 36 can be connected to the IO power processing modules 12C, and increased failure risk is avoided in the event that the connected IO power processing modules 12C cannot provide adequate power. With this in mind, the embodiment described below includes a test circuit system that facilitates testing the load current output from the redundant IO power processing modules 12C without altering the operation of the load 36. That is, these test operations do not use load 36, and thus do not use the signals sensed by load 36 when it is normally off or normally open.

[0033] As discussed above, two or more power supply processing modules can be arranged to provide power to shared or common loads. Figure 3 and Figure 4 Corresponding to the source Figure 2 Load current test of the redundant pairs of IO power processing modules 12C1 and 12C2. Figure 3 and Figure 4 This discussion pertains to two I / O power processing modules (I / O 12C). It should be understood that some examples may use more than two similar couplings as described herein to isolate test operations from power supply operations. For example, three or more I / O power processing modules may be coupled to the same shared load via corresponding diodes, with the cathode side coupled to that shared load. Before proceeding, it should be noted that... Figure 3 This is an example of an implementation method. That is, other suitable circuits can be used to implement the same method. Figure 3 The circuit described in the diagram performs the operation.

[0034] Now refer to Figure 3 , Figure 3This is a circuit diagram of a pair of I / O power processing modules 12C (e.g., I / O power processing module 12C1, I / O power processing module 12C2) coupled to supply power to load 36. The I / O power processing modules 12C can simultaneously supply power to load 36 via voltage supply 72A and voltage supply 72B. At any given time, one of the I / O power processing modules 12C can operate in primary supply mode, and the other I / O power processing module 12C can operate in an auxiliary supply role (e.g., auxiliary supply mode). In some systems, each of the I / O power processing modules 12C can alternate between operating in primary supply mode and auxiliary supply mode. When operating in auxiliary supply mode, the respective I / O power processing module can verify its output current (e.g., confirm that the output current is greater than or equal to the expected load current) without interrupting the power supply from the other I / O power processing module to load 36.

[0035] IO power processing modules 12C1 and 12C2 may each include test circuit systems 60A and 60B. Test circuit systems 60A and 60B may include or be coupled to voltage supplies 62A and 62B, which supply electrical signals to switches 64A and 64B (collectively referred to as switch 64), respectively. In some embodiments, voltage supplies 62A and 62B may include a control system, controller, microcontroller, microprocessor, or other suitable control device to control the operation of voltage supplies 62A and 62B. By way of example, control signals may be transmitted from processing module 12B, control system, test control system, microprocessor of voltage supply 62A, or other control circuit system to IO power processing module 12C1 to cause voltage supply 62A to output a pulse voltage to switch 64A. Therefore, switch 64A may be closed and the corresponding voltage supply 72A may be coupled to ground node 58A (e.g., ground terminal) via resistor 74A.

[0036] A pulse voltage can be supplied to the gate of switch 64A via timing circuitry 66A. Switch 64 can be any suitable type of switch, such as any suitable transistor. As described above, switch 64 can be closed when the pulse voltage signal transmitted from voltage supply 62 via timing circuitry 66 has a suitable voltage level for operating switch 64.

[0037] The timing circuit system 66 may include capacitors 68 and resistors 70 to form a resistor-capacitor (RC) circuit characterized by a time constant time period formed according to the values ​​of capacitors 68 and resistors 70. In this example, capacitors 68 may each have a capacitance value between 0.05 microfarads (μF) and 2 μF, and resistors 70 may each have a resistance value between 200 kiloohms (kΩ) and 300 kiloohms (kΩ). However, it should be noted that other suitable capacitors and resistors can be used to generate the desired decay time constant. One or more capacitors 68 and / or one or more resistors 70 may have any suitable values; for example, capacitors 68 may each have a capacitance value between 0.009 μF and 0.011 μF, and resistors 70 may each have a resistance value between 230.0 kΩ and 240.0 kΩ (e.g., 237 kΩ).

[0038] The capacitive coupling associated with the timing circuit system 66 prevents the firmware from attempting to apply a load beyond a threshold time. In effect, the time constant of the RC circuit formed by capacitor 68 and resistor 70 limits the time during which a pulse voltage signal can be supplied from voltage supply 62 to the gate of switch 64. That is, if firmware or control system operation causes a control signal to be supplied to voltage supply 62 for more than the threshold time, the RC circuit can attenuate the pulse voltage signal supplied to switch 64 to the threshold time. Thus, the test circuit system 60 can attenuate the control signal used to close switch 64 after a duration equal to the threshold time.

[0039] After closing, as described above, switch 64 delivers load current based on the voltage output from voltage supply 72 of IO power processing module 12C and the load current provided by resistor 74 coupled to switch 64. In this example, resistor 74 provides a total resistance between 9 ohms (Ω) and 13 Ω (e.g., 11.2 Ω), but it should be noted that any suitable load size can be used for testing based on the size of the resistance used as resistor 74. In practice, the two resistors can each have a resistance between 4.0 Ω and 6.0 Ω (e.g., 5.6 Ω). The sensing circuit can sense the voltage (Vt) across resistor 74 and switch 64, and the control system can use the sensed voltage to determine the load current from IO power processing module 12C.

[0040] In some implementations, the IO power processing module 12C may each include a current limiter 108. The current limiter 108 may include a corresponding switch that opens to provide current and voltage to the load 36. These current limiters 108 may also monitor the current from the voltage supply 72. The current limiter 108 may also include a fuse, a detection circuit system, or other suitable circuit protection components to help prevent current exceeding a certain threshold from being supplied to the load 36. When the current value is greater than or equal to the threshold, the current limiter 108 may disconnect and isolate the load 36 from the voltage supply 72.

[0041] As discussed above, in order to ensure that the current limiter 108, voltage supply 72, or another part of the IO power processing module 12C operates according to certain expected boundaries, the embodiment described below can be used to periodically or periodically test the ability of each of the IO power processing modules 12C to supply a threshold current amount to the load 36.

[0042] With this in mind, the test circuit system 60 (test circuit system 60A, test circuit system 60B) in each of the IO power processing modules 12C allows the control system to detect whether the IO power processing module 12C is able to provide load current to the load 36 at various times (e.g., different times). Specifically, the test circuit system 60 can perform a load current test on the IO power processing module 12C while avoiding providing a test load current to the load 36 and allowing the load 36 to continue its operation. That is, one of the IO power processing modules 12C can be tested regarding its current output capability while the other IO power processing module 12C can provide load current to the load 36 to allow the load 36 to continue operating. Furthermore, the test circuit system 60 can be used to test the current-providing capability of the IO power processing module 12C even when the load 36 is off. In other words, it is not necessary to turn on the load 36 to test the current-delivering capability of the IO power processing module 12C.

[0043] For clarity, IO power processing module 12C1 can be configured to provide the same load current as IO power processing module 12C2. Therefore, sometimes IO power processing module 12C1 can provide load current to load 36, while IO power processing module 12C2 may not provide any power or load current to load 36. In other instances, load 36 can receive current from both IO power processing modules 12C. In yet another example, the current supplied to load 36 can be switched between IO power processing modules 12C1 and IO power processing module 12C2. When load current is supplied to load 36 from one of the IO power processing modules 12C, the IO power processing module supplying the current can be considered the primary IO power processing module, and the other idle IO power processing module can be considered the redundant IO power processing module. When load current is simultaneously supplied to load 36 from IO power processing modules 12C, IO power processing modules 12C1 and IO power processing module 12C2 can alternate between a primary supply role and a secondary supply role. When operating in a secondary supply role, processing module 12B can perform background operations on the corresponding IO power processing module 12C without interrupting the total power supplied to load 36 by another IO power processing module 12C. Background activities may involve performance verification operations, testing operations, or diagnostic operations, including load current output verification operations performed using test circuitry system 60.

[0044] When operating in a secondary power supply role, the corresponding IO power processing module 12C can output less current compared to the IO power processing module 12C operating in a primary power supply role. When operating in a primary power supply role, the corresponding one of the IO power processing modules 12C can output its full output current (e.g., the rated load current for load 36) to load 36. The test circuit system 60 may include diodes 110 (diode 110A, diode 110B) to prevent current from being conducted to the opposite IO power processing module 12C.

[0045] Diode 110 is coupled such that its cathode side is coupled to load 36 and its anode side is coupled to the corresponding current limiter 108. The corresponding IO power processing module 12C can supply current to load 36 via the coupling to the anode of the corresponding diode 110. With this in mind, by way of example, when IO power processing module 12C2 is providing a lower current output than IO power processing module 12C1 (e.g., in an auxiliary supply role), IO power processing module 12C2 can output a lower voltage than IO power processing module 12C1. Therefore, diode 110B can become reverse biased and prevent current from flowing back to voltage supply 72B or test circuit system 60B through diode 110B.

[0046] To perform load current testing on a specific IO processing power supply module 12C, it will be assumed that IO power processing module 12C1 is operating as the primary power supply module and IO power processing module 12C2 may be operating as a secondary power supply module to describe the operation of the test circuit system 60. However, it should be noted that the implementation described herein can be implemented in the reverse manner.

[0047] Assuming the IO power processing module 12C2 operates in a supplementary supply role, the load 36 can independently receive the desired load current from the IO power processing module 12C1. Therefore, the IO power processing module 12C2 can be tested to verify that it can generate a threshold current sufficient to independently energize the load 36. In some embodiments, a control system such as processing module 12B can be used to initiate testing of the IO power processing module 12C2 while allowing the load 36 to continue its normal or planned operation.

[0048] By operation, the control system can transmit control signals to circuit components (e.g., switches) of the test circuit system 60B to couple voltage supply 62B to switch 64B. Therefore, switch 64B can be closed and voltage supply 72B can be coupled to ground via resistor 74B. The current output via voltage supply 72B can generate a voltage (VtB) across resistor 74B. The voltage (VtB) across resistor 74B can be sensed by the control system and correlated with a current measurement based on the resistance characterizing resistor 74B. The control system can then compare the calculated current with a threshold current corresponding to the rated output current for the IO power processing module 12C2. Deviation from the threshold current (e.g., a defined deviation margin or percentage above or below the threshold current) can cause the control system to generate an alarm or notification to allow the operator to be aware of the deviation. In some embodiments, the control system can adjust the operation of load 36 to operate such that the calculated current is sufficient to perform its operation.

[0049] To help illustrate, Figure 4 This is a flowchart of a process 120 for operating a control system such as processing module 12B to test the load current of the corresponding IO power processing module 12C without turning the load 36 on or off. Process 120 can be executed by processing module 12B, another control system associated with the distributed processing system 10, etc., in response to executing instructions stored in a tangible, non-transitory computer-readable medium, such as the memory of processing module 12B, or another suitable memory. Furthermore, the operation of process 120 is shown in a specific order; however, some operations may be performed in a different order than presented. Certain voltage and current values ​​are described herein, but it should be understood that these are example values ​​and example ranges and can be adjusted for specific systems and implementations.

[0050] At block 124, processing module 12B may receive a request to verify the current output from IO power processing module 12C1 or IO power processing module 12C2. For ease of discussion, the operation of process 120 is described with reference to IO power processing module 12C2 being tested, and it should be understood that these descriptions are similarly applied to both IO power processing modules 12C. Requests may be generated by an application running on the firmware of processing module 12B to track the operating intervals of IO power processing module 12C1 (e.g., when the corresponding IO power processing module 12C is operated in an auxiliary supply role), the operating intervals of IO power processing module 12C2, or both. Sometimes processing module 12B may receive requests via IO block 16, for example, from another processing module 12, from an external device, a user, via communication bus 14, etc.

[0051] At block 126, processing module 12B can determine whether a power supply (e.g., IO power processing module 12C2) is providing an auxiliary supply level voltage to load 36. This check determines whether IO power processing module 12C2 is operating in its auxiliary supply role and is thus eligible to test its load current output. For this purpose, processing module 12B can receive voltage data sensed across current limiter 108B, voltage supply 72B, or another suitable portion of the circuitry of IO power processing module 12C2. Processing module 12B can compare the voltage data with a threshold voltage amount to determine whether the voltage data value indicates that IO power processing module 12C2 is providing an auxiliary supply level voltage to load 36. For example, the primary supply level voltage may be equal to 24V or a value between 22V and 26V, and the auxiliary supply level voltage may be equal to 20V or a value between 18V and 22V. In response to determining that the IO power processing module 12C2 is not providing an auxiliary supply level of voltage to the load 36, the processing module 12B may repeat the determination operation of block 126 until the IO power processing module 12C2 provides an auxiliary supply level of voltage.

[0052] However, in response to determining the voltage level at which the IO power processing module 12C2 provides an auxiliary supply to the load 36, at block 128, the processing module 12B can transmit a control signal to the IO power processing module 12C2 to cause the test circuit system 60B to output a pulse voltage signal transmitted from the voltage supply 62B. After the switch 64B receives the pulse voltage signal transmitted from the voltage supply 62B, a sensing circuit system such as sensing device 34 can sense the voltage (VtB) across resistor 74B. At block 130, the processing module 12B can receive voltage data from a sensing device such as sensing device 34 for a period of time after the control signal is transmitted.

[0053] In response to receiving voltage data, at block 132, processing module 12B can determine whether the voltage data is within a threshold range of the expected voltage data value. The expected voltage data value can be equal to or based on a voltage determined by multiplying the rated (or desired output) current value for IO power processing module 12C2 by the resistance of resistor 74B. The target current value can correspond to the rated current value of IO power processing module 12C2 or be within a threshold range of the rated current value. In some cases, this may also include logging the voltage data in a data history log.

[0054] If processing module 12B determines that the voltage data is within a threshold range or equal to the expected voltage data, then processing module 12B may record the data value and wait for the next instruction to repeat the operation (e.g., at block 124). However, if processing module 12B determines that the voltage data is outside or not within the threshold range of the expected voltage data, then at block 134, processing module 12B may perform an operation based on the voltage data. As part of the operation, processing module 12B may adjust the operation of the distributed processing system 10 and / or may generate alarm signals or otherwise alert another control system or operator. Processing module 12B may generate alarm data indicating that the IO power processing module 12C2 is not outputting current according to its rated current value, for example, triggering the generation of graphical or indicative alarm data on the graphical user interface.

[0055] Note that the control system, such as processing module 12B, can test the output current of IO power processing module 12C1 at a different start time than the test performed on IO power processing module 12C2. Furthermore, after determining that one of the IO power processing modules 12C is in an auxiliary supply role (e.g., as an auxiliary power supply), the control system can repeatedly couple voltage supply 72 to resistor 74 via test circuit system 60, thereby repeatedly testing the output current from voltage supply 72. Repeated testing can occur periodically or at set intervals to confirm that the IO power processing module 12C is capable of providing the rated current. When it is determined that another IO power processing module 12C actively provides a current signal to load 36, the determination can be repeated, and tests on other IO power processing modules 12C in a primary supply role can be skipped or delayed. In this way, one or more of the IO power processing modules 12C can be tested two or three times (or more) between each test of another IO power processing module 12C.

[0056] Control systems may include processors and can be considered electronic devices with input / output devices, memory, etc. Therefore, a control system may include a tangible, non-transitory, computer-readable medium storing instructions executable by a processor, which, when executed by the processor, cause the processor to perform various operations, such as testing the output current of a power I / O module (e.g., an I / O power processing module). Furthermore, an I / O power processing module can be considered a power device. Similarly, these systems and methods can be applied to other power devices that supply loads that are not intended to be turned on or off for testing, such as any suitable analog or digital power supply, power bus connections, etc. Additionally, note that each power device or I / O power processing module may be expected to output current at a rated current value, and each rated current value may correspond to a rated voltage value.

[0057] To further illustrate the test operation and diodes 110, the IO power processing module 12C can be coupled to the load 36 via one or more diodes 110 arranged with their anodes facing the voltage supply 72. In this way, the respective IO power processing module 12C supplies current to the load 36 via coupling to the anode of the respective diode 110. For example, IO power processing module 12C1 can output current via a path coupled to the anode of diode 110A, which outputs current to the load 36 via its cathode, and to the cathode of diode 110B, which can be reverse-biased to prevent current from flowing through it. Diode 110B can be coupled at its anode to a path used by IO power processing module 12C2 to deliver its output current to the load 36, a path that can be shared by IO power processing modules 12C coupled as a redundant or concurrent pair. In practice, diodes 110 can be coupled to each other at their cathodes, and thus reverse-coupled to each other. When the anodes are at the same voltage level, both diodes allow current to flow from the respective IO power processing module 12C to the load 36. However, when one of the IO power processing modules 12C enters an operational test mode and reduces its output current to the load 36, its corresponding diode 110 becomes reverse biased and blocks current from one or more other IO power processing modules 12C. Therefore, this arrangement temporarily isolates the module under test from the other IO power processing modules 12C to reduce the possibility of current interference from the test operation affecting the operation of the load 36. That is, by reducing the possibility of interference with the ongoing operational state of the load 36, such as normally off or normally on, or by preventing interference with the ongoing operational state of the load 36, the test operation is improved by enabling online testing of redundant pairs of IO power modules without using the operation of the load 36 during online testing.

[0058] During non-test operations, both the primary I / O power processing module 12C1 and the auxiliary I / O power processing module 12C2 can supply the same or substantially similar voltage, such as 24 volts (V), to the shared load 36. However, to enter test mode to test the auxiliary I / O power processing module 12C2, the control system can operate the auxiliary I / O power processing module 12C2 in a reduced voltage state to trigger isolation of the output of the auxiliary I / O power processing module 12C2 from the shared load 36 for a specified duration. During this duration, the primary I / O power processing module 12C1 can supply a higher voltage, such as 24 V to 20 V, to the shared load compared to the auxiliary I / O power processing module 12C2, allowing the auxiliary I / O power processing module 12C2 to be tested without interfering with the power supply to the shared load 36. Note that the operating state of the shared load 36 does not change during the test operation. That is, the test operation does not turn on the shared load 36 when it is off and waiting to be turned on, or the test operation does not turn off the shared load 36 when it is on. Therefore, the online current output verification operation can be performed without affecting the normal process and / or the operating state of load 36.

[0059] Therefore, these systems and methods can be useful in a variety of applications to improve test operations. For example, when a system is expected to supply power from the main IO power processing module and the auxiliary IO power processing module 12C to a normally off load 36, the test systems and methods described herein can be used to verify that the current output matches or is substantially similar to the rated current of the IO power processing module 12C (within the threshold of the rated current of the IO power processing module 12C). In another system, where it may be expected to supply power from the main IO power processing module and the auxiliary IO power processing module 12C to a normally open load 36, the test systems and methods described herein can be used to verify the operation of one or both of the IO power processing modules 12C to verify that the current output matches or is substantially similar to the rated current output of the IO power processing module 12C (within the threshold of the rated current of the IO power processing module 12C). In practice, these systems and methods can be used in systems with concurrent power supplies, redundant power supplies, backup power supplies, power supplies implemented as IO power processing modules or other power delivery circuit systems, or other similar circuit systems, to improve how to test load current in systems where the operation of the desired load does not change or interrupt.

[0060] The technical advantages of the systems and methods described herein include in-line current testing systems and methods for testing in-line load current using circuitry other than the load. When a system (e.g., an I / O power processing module) is expected to reliably supply power to a load according to commands, it is desirable to test the system to verify its ability to output load current at current values. Furthermore, using test methods independent of load switching can be beneficial for systems used in applications tested by switching on the load, such as fire extinguishing systems. Therefore, the systems and methods described herein test the load current supplied by the system without switching the load on or off. These systems and methods use pulse control signals to activate a switch over a relatively short period to redirect the supplied voltage from the load supply to a resistor. The voltage transmitted via the resistor is sensed and correlated with the load current of the system under test. Based on the value of the load current of the system under test, the current testing system can verify the system when it generates current at its rated current value, or reject the system when it does not generate current at its rated current value or a threshold of its rated current value. The systems and methods described herein can detect not only when the voltage supply fails to generate the rated voltage amount, but also when other components of the system fail to operate according to their rated performance. The described test circuit system may also include a series capacitor coupled to a parallel resistor to form a timing circuit system. This timing circuit system has a time constant that allows the pulsed voltage signal delivered from the voltage supply of the test circuit system to decay for a duration longer than desired, to the point of negligible impact on the downstream circuit system. This decay improves the resilience of the test circuit system and reduces the likelihood of firmware malfunctions at the upstream control system damaging the test circuit system and / or the system under test by applying the test voltage for a longer than desired time. The time constant decay protection also allows for the use of smaller resistors in the test circuit system because the test pulse has a programmed pulse duration based on the time period for which it is applied and / or the time constant of the capacitance and resistance of the test circuit system. Furthermore, operation is additionally improved when using a test circuit system with concurrent or redundant power supplies because the reverse bias of the diodes helps isolate the primary power supply from the power supply under test.

[0061] While only certain features of this disclosure have been shown and described herein, many modifications and variations will occur to those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and variations that fall within the true spirit of this disclosure.

Claims

1. A system for supplying power to a load, comprising: A voltage supply configured to supply output current to a load; A test circuit system coupled to the voltage supply, wherein the test circuit system includes: Additional voltage supply; A switch, configured to close in response to a voltage signal from the additional voltage supply; and A current measurement circuit is configured to be coupled to the switch, wherein the current measurement circuit is configured to receive the output current from the voltage supply when the switch is closed and the voltage supply operates as an auxiliary supply for the load; A diode coupled to the load, wherein the anode of the diode is positioned facing the voltage supply; and The control system is configured to: When the switch is closed, the voltage across the current measuring circuit is received from the sensing circuit. The amount of current present in the output current is determined based on the resistance value associated with the current measuring circuit and the voltage; and The operation is performed based on the current quantity.

2. The system according to claim 1, wherein, The control system is configured to: Compare the current quantity with the rated output current associated with the voltage supply; and The operation is performed based on the current quantity being within a threshold amount relative to the rated output current.

3. The system according to claim 1, comprising a current limiter and a diode, wherein, The input to the current limiter is coupled to the voltage supply; The output from the current limiter is coupled to the anode of the diode; as well as The load is coupled to the cathode of the diode.

4. The system according to claim 1, wherein, The test circuit system includes a timing circuit configured to limit the amount of time for which the voltage signal is applied to the switch.

5. The system according to claim 4, wherein, The timing circuit includes at least one capacitor and at least one resistor associated with a time constant time period.

6. The system according to claim 1, comprising: A second voltage supply is coupled to the load; as well as A second test circuit system, wherein the second test circuit system is configured to test a second output current from the second voltage supply at a different time than that of the test circuit system.

7. The system according to claim 6, wherein, The control system is configured to: Determine the second voltage supply to assist the supply role in operation; and In response to the second voltage supply, the auxiliary supply role is operated as follows: The second test circuit system is configured to repeatedly couple the second voltage supply to one or more second resistors via the second switch; as well as Determine whether the amount of the second current present in the second output current is within the threshold amount of the rated output current associated with the second voltage supply.

8. The system according to claim 7, wherein, The voltage supply is configured to output the output current to the load when the second test circuit system determines that the second current quantity is within the threshold quantity of the rated output current.

9. The system according to claim 1, wherein, The current measuring circuit includes one or more resistors.

10. A test circuit for testing the voltage supply of a load, comprising: Additional voltage supply; A switch configured to close in response to receiving a voltage signal from the additional voltage supply; A timing circuit coupled to the additional voltage supply and ground terminal, wherein the timing circuit is configured to limit the amount of time for which the voltage signal is provided to the switch; A current measurement circuit configured to be coupled to the switch, wherein the current measurement circuit is configured to receive an output current from the voltage supply during the specified time period when the switch is closed and the voltage supply operates as an auxiliary supply to the load; and A diode coupled to the load, wherein the anode of the diode is positioned facing the voltage supply.

11. The test circuit according to claim 10, wherein, The timing circuit includes at least one capacitor and at least one resistor associated with a time constant time period, the time constant time period being configured to limit the amount of time for which the voltage signal is applied to the switch.

12. The test circuit according to claim 11, wherein, The current measuring circuit includes one or more resistors.

13. The test circuit according to claim 12, wherein, The switch is configured to be coupled to a first resistor, wherein the first resistor is configured to be coupled in series to a second resistor, and the second resistor is coupled to the ground terminal.

14. The test circuit according to claim 10, wherein, The switch is configured to be coupled to the anode of the diode, which is coupled to the additional voltage supply via a current limiter.

15. A tangible non-transitory computer-readable medium configured to store instructions executable by a processor of an electronic device, the instructions causing the processor, when executed by the processor, to: Receive an indication of a request to verify the output current of the first input / output power supply module configured to be coupled to the load; The switch is closed for a specified duration in response to the instruction of the request; In response to determining the level of auxiliary power supply provided by the power supply module to the load, the voltage across one or more resistors coupled between the switch and the ground terminal is detected; The amount of current present in the output current transmitted via the one or more resistors is determined based on the resistance value of the one or more resistors and the voltage. as well as A notification is transmitted in response to the difference between the current quantity and the rated output current being greater than a threshold quantity.

16. The tangible non-transitory computer-readable medium of claim 15, storing instructions which, when executed by the processor, cause the processor to compare the current quantity with the rated output current supplied by the voltage of the first input / output power supply module.

17. The tangible non-transitory computer-readable medium of claim 15, storing instructions which, when executed by the processor, cause the processor to close an additional switch in response to a request to verify an additional output current of the second input / output power supply module.

18. The tangible non-transitory computer-readable medium according to claim 17, wherein, The voltage supply of the first input / output power supply module is configured to output the output current to the load when the additional switch of the second input / output power module is closed.

19. The tangible non-transitory computer-readable medium of claim 15, storing an instruction, when executed by the processor, to cause the processor to transmit a voltage pulse to the switch in response to receiving an instruction to request the request, wherein, The voltage pulse is configured to close the switch for the duration stated.

20. The tangible non-transitory computer-readable medium according to claim 15, wherein, The first input / output power supply module is configured to attenuate the control signal used to close the switch after the duration is stated.

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