A small black box processor circuit with load detection function

Abstract

This utility model relates to a small black box processor circuit with load detection function, including a power supply module, a detection module, an indicator module, and a load to be tested, Rload. The power supply module includes a power supply V1 to power the entire circuit. The detection module includes a voltage regulator component, a current sampling component, and a switch control component, which respectively realize the functions of voltage stabilization, load current acquisition with reverse protection, and control of the indicator module's on / off state based on the current status. The indicator module provides status indication through LED1 (load current exceeds normal set value), LED2 (load short circuit), and LED3 (load current normal). Using this circuit solves the problems of existing load product testing relying on operational amplifiers, independent processing units, and external display devices, resulting in low integration, unintuitive fault identification, and cumbersome operation. It can be efficiently applied to product factory performance testing and quickly screen qualified products.

Description

Technical Field

[0001] This utility model relates to the field of detection circuit technology, specifically a small black box processor circuit with load detection function. Background Technology

[0002] The "Little Black Box" processor typically features a black casing and is generally compact, with dimensions ranging from ≤400mm in length to ≤300mm in width and ≤60mm in height. Internally, it integrates a control module and a power module, boasting powerful computing capabilities and processing speed, enabling it to control loads. Loads often refer to electrical appliances such as ambient lighting, sensors, and circuit breakers. Ambient lighting, a common component in home décor and automotive interiors, requires stable current operation and load safety as core indicators of product quality testing. Current ambient lighting testing largely relies on traditional discrete circuit solutions, necessitating separate current acquisition circuits, operational amplifier modules, and independent processing units, along with external display devices for fault alerts. This results in a fragmented system with low integration, occupying significant space and requiring professionals to interpret values ​​or codes on the display to determine load status. This approach is cumbersome and inefficient, hindering rapid fault identification. Utility Model Content

[0003] The purpose of this invention is to provide a small black box processor circuit with load detection function, which solves the problems of unintuitive fault identification and cumbersome operation in the existing structure.

[0004] The technical solution of this utility model is: a small black box processor circuit with load detection function, characterized in that: it includes a power supply module, a detection module, an indicator module, and a load Rload to be detected;

[0005] The power module includes a power supply V1, which supplies power to the entire circuit.

[0006] The detection module is used to detect the operating current state of the load Rload, and it includes a voltage regulation component, a current sampling component, and a switch control component.

[0007] The voltage regulator assembly is used to stabilize the output V1 of the power module to V2. It includes transistors Q2 and Q5, a Zener diode D3, and resistors R9, R11, R13, R14, R15, and R16. The positive terminal of V1 is connected to the load Rload. Q2 is connected to the positive terminal of V1, Q5, and the load Rload. Q5 is connected to the negative terminal of Q2 and D3, as well as the connection line between Q2 and the load Rload. The positive terminal of D3 is grounded. One end of R9 is connected to the connection line between the positive terminal of V1 and Q2, and the other end is connected to the connection line between Q2 and Q5. R11 is connected in series between R9 and Q5. One end of R13 is connected to the positive terminal of V1, and the other end is connected to the connection line between Q5 and the negative terminal of D3. R14 is connected in series with the connection line between Q5 and the load Rload. R16 is connected to the connection line between Q5 and R14 and grounded. R15 is connected to the connection line between the positive terminal of V1 and the load Rload and grounded.

[0008] The current sampling component is used to collect the operating current of the load Rload and prevent the reverse current flow in the circuit from damaging the components. It includes a resistor R3, a transistor Q1 and a diode D1; Q1 is connected to the positive terminal of V1, the positive terminal of D1 and Q2 respectively, the negative terminal of D1 is connected to the connection line between Q2 and the load Rload, and one end of R3 is connected to the positive terminal of V1 and the other end is connected to Q1, Q2 and R9.

[0009] The switch control component is used to control the on / off state of the indicator circuit according to the load current state Rload, and includes resistors R1, R6, R10, R12, diode D2, and transistors Q3 and Q4.

[0010] R1 and D2 are connected in series in the connection line between the positive terminal of V1 and the load Rload, with the positive terminal of D2 connected to R1 and the negative terminal connected to the load Rload. R10 and R12 are connected in series, with R10 connected to the connection line between Q1 and the positive terminal of D1, and R12 grounded. One end of R6 is connected to the connection line between R1 and D2, and the other end is connected to R15. Q4 is connected to the connection line between the positive terminal of V1 and R1, and the connection line between R6 and R15, and grounded. Q3 is connected to the connection line between R10 and R12, and the connection line between the positive terminal of V1 and R1, and grounded. The indicating module includes resistors R2, R4, and R5, and light-emitting diodes LED1 and LED2. D2, LED3; One end of R2 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q3. The positive terminal of LED3 is connected to the connection line between R2 and Q3, and its negative terminal is grounded. One end of R4 is connected to the connection line between Q1 and R10, and the other end is connected to the positive terminal of LED1. The negative terminal of LED1 is grounded. One end of R5 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q4. The positive terminal of LED2 is connected to the connection line between R5 and Q4, and its negative terminal is grounded. LED1 is used to indicate that the load Rload current exceeds the normal set value, LED2 is used to indicate that the load Rload is short-circuited, and LED3 is used to indicate that the load Rload current is normal.

[0011] This utility model has the following advantages:

[0012] 1. Integrated testing simplifies the testing system.

[0013] By integrating the power supply module, detection module (voltage regulator, current sampling module, and switch control module), and indicator module (LED1-LED3 and current-limiting resistors) into a single design, the system eliminates the need for separate current acquisition circuits, operational amplifier modules, independent processing units, and external display devices, as required by existing technologies. This significantly reduces system fragmentation. This integrated structure not only reduces the space required for testing equipment but also eliminates the wiring and debugging steps between discrete modules, resolving the "cumbersome operation" problem of existing devices. It is particularly well-suited to the high-efficiency requirements of mass production testing for ambient lighting.

[0014] 2. Intuitive status indicators for quick fault identification.

[0015] By clearly defining functional divisions (LED1 indicates current exceeding the set value, LED2 indicates short circuit, and LED3 indicates normal operation), and combining the linkage logic between the switch control component and the detection module, a clear effect of "light illumination corresponding to the fault type" is achieved. Testers do not need to interpret the values ​​or codes on the display device; they can determine the working status of the load Rload within one second simply by observing the on / off state of the LEDs. This completely solves the core pain point of existing technologies—"fault identification is not intuitive"—and significantly improves the screening efficiency of ambient lighting products.

[0016] 3. A stable testing environment ensures accurate testing.

[0017] The voltage regulator assembly (Q2, Q5, D3, and multiple resistors) stabilizes the power supply V1 to a preset voltage V2, ensuring that all loads under test (such as ambient lights) are tested under a uniform voltage, avoiding current detection errors caused by input voltage fluctuations. Simultaneously, diode D1 in the current sampling assembly prevents reverse current flow in the circuit, effectively protecting transistor Q1 and other components from damage and ensuring the stability of the testing process. This design makes the test results more accurate, reliably screening out ambient light products with normal current, excessive threshold current, or short-circuit faults, meeting the stringent standards of factory performance testing.

[0018] A further feature of this invention is that the preset voltage V2 output by the voltage regulator component satisfies the following relationship: V2≈[(V3+V PN_Q5 [(R14+R16)] / R16; where V3 is the voltage regulation value of Zener diode D3, V PN_Q5 This is the PN junction turn-on voltage of transistor Q5.

[0019] By further configuring the above settings and clarifying the calculation formula for the output voltage V2 of the voltage regulator component, the voltage regulator D3, transistor Q5, and resistors R14 and R16 with corresponding parameters can be selected according to actual test requirements to stabilize the voltage at the preset value V2, ensuring that all ambient light loads are tested under the same voltage, thereby improving the accuracy and consistency of the test results.

[0020] A further feature of this invention: when the load current Rload is within the normal range of 0A to IA... nomal At time A, the voltage V collected by resistor R3 is designed to be... sensor_R3 < The PN junction forward voltage V of transistor Q1 PN_Q1 When transistor Q1 is cut off, LED1 is not lit; when diode D1 is reverse biased, the collector voltage V of Q1 is... c_Q1 < The PN junction forward voltage V of transistor Q3 PN_Q3 When Q3 is cut off, V1 provides operating current to LED3 after being current-limited by R2, and LED3 lights up. Because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, and V1 makes Q4 saturate and conduct through R1 and R6. The collector of Q4 outputs a low level, and LED2 does not light up.

[0021] By adopting the above further settings, the working status of each component in the circuit and the display logic of the indicator module are clearly defined under normal load conditions. The intuitive indication method of only LED3 being lit can quickly determine that the ambient light load current is normal without the need to interpret complex data, thus improving testing efficiency.

[0022] A further feature of this invention: when the load current Rload is within the abnormal range value I... nomal A~I abnomal_1 At time A, the voltage V collected by resistor R3 is designed to be... sensor_R3 > The PN junction forward voltage V of transistor Q1 PN_Q1 Transistor Q1 operates in amplification mode, and the high-level output from the collector of Q1 illuminates LED1; simultaneously, the high-level output from the collector of Q1, through R10, causes Q3 to saturate and conduct, with its saturation voltage V. sat_Q3 < LED3's forward voltage V led3， LED3 is off; because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, Q4 is saturated and conducting, and the collector of Q4 outputs a low level, so LED2 does not light up.

[0023] By adopting the above further settings, the circuit workflow when the load current exceeds the set value is clearly defined. By using the combination of LED1 being lit and LED3 being off, the problem of excessive load threshold current of ambient lights can be intuitively identified, making it easy to quickly screen out products with abnormal current and ensure that the performance of products leaving the factory is qualified.

[0024] A further feature of this invention: when the load Rload is short-circuited, the voltages of diodes D1 and D2 are clamped to V respectively. doide_D1 V doide_D2 Design V doide_D1 <V PN_Q4 V doide_D2 <V PN_Q3 V PN_Q4 The PN junction turn-on voltage of transistor Q4, V PN_Q3 When the PN junction of transistor Q3 is turned on, transistors Q3 and Q4 are turned off, and LED1 and LED2 are not lit. When transistor Q3 is turned off, V1 is limited by resistor R2, which lights up LED3.

[0025] By adopting the above-mentioned further settings, the circuit protection and indication logic under the load short circuit condition is clearly defined. The clamping effect of diodes D1 and D2 can prevent large current from damaging components. At the same time, the indication method of only LED3 lighting up can quickly identify the ambient light load short circuit fault, making it easy to remove faulty products in time.

[0026] A further feature of this invention is that the load Rload is an ambient light, and the small black box processor circuit is used for factory performance testing of the ambient light product.

[0027] By adopting the above-mentioned further settings, clarifying the specific application scenarios and load types of the circuit, and designing for the factory testing requirements of ambient lighting products, it can efficiently realize the detection of ambient lighting current stability and load safety, solve the drawbacks of traditional testing devices, and improve the efficiency and accuracy of factory testing. Attached Figure Description

[0028] Figure 1 This is a circuit block diagram of a specific embodiment of the present utility model;

[0029] Figure 2 This is a circuit schematic diagram of a specific embodiment of the present invention. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings:

[0031] like Figure 1-2 As shown, a small black box processor circuit with load detection function includes a power supply module, a detection module, an indicator module, and a load Rload to be detected.

[0032] The power module includes a power supply V1, which supplies power to the entire circuit.

[0033] The detection module is used to detect the operating current state of the load Rload, and it includes a voltage regulation component, a current sampling component, and a switch control component.

[0034] The voltage regulator component is used to stabilize the output V1 of the power module to V2, ensuring that the load Rload is tested under a uniform voltage. It includes transistors Q2 and Q5, a Zener diode D3, and resistors R9, R11, R13, R14, R15, and R16. The positive terminal of V1 is connected to the load Rload. Q2 is connected to the positive terminal of V1, Q5, and the load Rload. Q5 is connected to the negative terminals of Q2 and D3, as well as the connection line between Q2 and the load Rload. The positive terminal of D3 is grounded. One end of R9 is connected to the positive terminal of V1. The connection line to Q2 is connected at one end, and the connection line between Q2 and Q5 is connected at the other end. R11 is connected in series between R9 and Q5. One end of R13 is connected to the positive terminal of V1, and the other end is connected to the connection line between Q5 and the negative terminal of D3. R14 is connected in series on the connection line between Q5 and the load Rload. R16 is connected to the connection line between Q5 and R14 and grounded. R15 is connected to the connection line between the positive terminal of V1 and the load Rload and grounded. The preset voltage V2 output by the voltage regulator component satisfies the following relationship: V2≈[(V3+V PN_Q5 [(R14+R16)] / R16; where V3 is the voltage regulation value of Zener diode D3, V PN_Q5 This is the PN junction turn-on voltage of transistor Q5.

[0035] The current sampling component is used to collect the operating current of the load Rload and prevent the reverse current flow in the circuit from damaging the components. It includes a resistor R3, a transistor Q1 and a diode D1; Q1 is connected to the positive terminal of V1, the positive terminal of D1 and Q2 respectively, the negative terminal of D1 is connected to the connection line between Q2 and the load Rload, and one end of R3 is connected to the positive terminal of V1 and the other end is connected to Q1, Q2 and R9.

[0036] The switch control component is used to control the on / off state of the indicator circuit according to the load current state Rload, and includes resistors R1, R6, R10, R12, diode D2, and transistors Q3 and Q4.

[0037] R1 and D2 are connected in series in the connection line between the positive terminal of V1 and the load Rload, with the positive terminal of D2 connected to R1 and the negative terminal connected to the load Rload. R10 and R12 are connected in series, with R10 connected to the connection line between Q1 and the positive terminal of D1, and R12 grounded. One end of R6 is connected to the connection line between R1 and D2, and the other end is connected to R15. Q4 is connected to the connection line between the positive terminal of V1 and R1, and the connection line between R6 and R15, and grounded. Q3 is connected to the connection line between R10 and R12, and the connection line between the positive terminal of V1 and R1, and grounded. The indicating module includes resistors R2, R4, and R5, and light-emitting diodes LED1 and LED2. D2, LED3; One end of R2 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q3. The positive terminal of LED3 is connected to the connection line between R2 and Q3, and its negative terminal is grounded. One end of R4 is connected to the connection line between Q1 and R10, and the other end is connected to the positive terminal of LED1. The negative terminal of LED1 is grounded. One end of R5 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q4. The positive terminal of LED2 is connected to the connection line between R5 and Q4, and its negative terminal is grounded. LED1 is used to indicate that the load Rload current exceeds the normal set value, LED2 is used to indicate that the load Rload is short-circuited, and LED3 is used to indicate that the load Rload current is normal.

[0038] In this circuit, R3 is used to collect the operating current of the load Rload, D1 prevents reverse current flow from damaging components, and Q1 switches its operating state according to the magnitude of the sampled voltage. R2, R4, and R5 all serve to limit current, preventing excessive current from burning out the LED. The load Rload is an ambient light, and this small black box processor circuit is used for factory performance testing of ambient light products.

[0039] When the load Rload (ambient light) is connected to the circuit and the current is within the normal range, the normal range value is set to 0A~1A. nomal A, the voltage V collected by resistor R3 sensor_R3 ≈I nomal *R3, Design V sensor_R3 <V PN_Q1 V PN_Q1 The voltage across the PN junction of transistor Q1 is the on-state voltage, therefore transistor Q1 is cut off, and LED1 does not light up due to no current input; simultaneously, the cutoff of Q1 reverse-biases diode D1, and the collector voltage V of Q1... c_Q1 ≈0V, and V c_Q1 <V PN_Q3 V PN_Q3 The PN junction of transistor Q3 is turned on, Q3 is off, and V1, after being current-limited by R2, provides the operating current for LED3, causing LED3 to light up. Because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, and V1 forms a path through R1 and R6, causing Q4 to saturate and conduct. The collector of Q4 outputs a low level, and LED2 does not light up. At this time, only LED3 is lit, indicating that the ambient light load current is normal and the product is qualified.

[0040] When the current of the load Rload exceeds the normal set value, i.e., it is in the abnormal range value I. nomal A~I abnomal_1 At time A, the voltage V collected by resistor R3 sensor_R3 ≈I abnomal_1 A*R3, V sensor_R3 >V PN_Q1 V PN_Q1 The PN junction turn-on voltage of transistor Q1 is the voltage across the transistor. Transistor Q1 operates in amplification mode, and the collector of Q1 outputs a high level. Current flows through resistor R4 into LED1, lighting LED1. Simultaneously, the high level at the collector of Q1, through resistor R10, causes Q3 to saturate and conduct, with its saturation turn-on voltage V0. sat_Q3 ≈0.1~0.2V, V sat_Q3 < LED3's forward voltage V led3， LED3 is turned off because it cannot obtain sufficient conduction voltage; in addition, because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, Q4 is saturated and conducting, and the collector of Q4 outputs a low level, so LED2 does not light up. At this time, only LED1 is lit, indicating that the load threshold current of the ambient light is too high, and the product is unqualified.

[0041] When the load Rload is short-circuited, the voltages of diodes D1 and D2 are clamped to V respectively. doide_D1 V doide_D2 And design V doide_D1 <V PN_Q4 V doide_D2 <V PN_Q3 V PN_Q4 The PN junction turn-on voltage of transistor Q4, V PN_Q3 The PN junction of transistor Q3 is the on-state voltage, therefore transistors Q3 and Q4 are cut off. Q4 being cut off means LED2 receives no current and does not light up. After Q3 is cut off, power supply V1, through resistor R2, provides operating current to LED3, causing LED3 to light up. Simultaneously, because the circuit lacks sufficient voltage to turn on Q1, LED1 also does not light up. The fact that only LED3 is lit at this point indicates a short circuit fault in the ambient light load, making the product defective.

[0042] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A small black box processor circuit with load detection function, characterized in that: It includes a power module, a detection module, an indicator module, and the load to be detected, Rload; The power module includes a power supply V1, which supplies power to the entire circuit. The detection module is used to detect the operating current state of the load Rload, and it includes a voltage regulation component, a current sampling component, and a switch control component. The voltage regulator assembly is used to stabilize the output V1 of the power module to V2. It includes transistors Q2 and Q5, a Zener diode D3, and resistors R9, R11, R13, R14, R15, and R16. The positive terminal of V1 is connected to the load Rload. Q2 is connected to the positive terminal of V1, Q5, and the load Rload. Q5 is connected to the negative terminal of Q2 and D3, as well as the connection line between Q2 and the load Rload. The positive terminal of D3 is grounded. One end of R9 is connected to the connection line between the positive terminal of V1 and Q2, and the other end is connected to the connection line between Q2 and Q5. R11 is connected in series between R9 and Q5. One end of R13 is connected to the positive terminal of V1, and the other end is connected to the connection line between Q5 and the negative terminal of D3. R14 is connected in series with the connection line between Q5 and the load Rload. R16 is connected to the connection line between Q5 and R14 and grounded. R15 is connected to the connection line between the positive terminal of V1 and the load Rload and grounded. The current sampling component is used to collect the operating current of the load Rload and prevent the reverse current flow in the circuit from damaging the components. It includes a resistor R3, a transistor Q1 and a diode D1; Q1 is connected to the positive terminal of V1, the positive terminal of D1 and Q2 respectively, the negative terminal of D1 is connected to the connection line between Q2 and the load Rload, and one end of R3 is connected to the positive terminal of V1 and the other end is connected to Q1, Q2 and R9. The switch control component is used to control the on / off state of the indicator circuit according to the current state of the load Rload. It includes resistors R1, R6, R10, R12, diode D2, and transistors Q3 and Q4. R1 and D2 are connected in series in the connection line between the positive terminal of V1 and the load Rload, and the positive terminal of D2 is connected to R1 and the negative terminal is connected to the load Rload. R10 and R12 are connected in series. R10 is connected to the connection line between Q1 and the positive terminal of D1. R12 is grounded. One end of R6 is connected to the connection line between R1 and D2, and the other end is connected to R15. Q4 is connected to the connection line between the positive terminal of V1 and R1, the connection line between R6 and R15, and grounded. Q3 is connected to the connection line between R10 and R12, the connection line between the positive terminal of V1 and R1, and grounded. The indicator module includes resistors R2, R4, and R5, and light-emitting diodes LED1, LED2, and LED3. One end of R2 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q3. The positive terminal of LED3 is connected to the connection line between R2 and Q3, and its negative terminal is grounded. One end of R4 is connected to the connection line between Q1 and R10, and the other end is connected to the positive terminal of LED1, and the negative terminal of LED1 is grounded. One end of R5 is connected to the connection line between the positive terminal of V1 and R1, and the other end is connected to Q4. The positive terminal of LED2 is connected to the connection line between R5 and Q4, and its negative terminal is grounded. LED1 is used to indicate that the load Rload current exceeds the normal set value, LED2 is used to indicate that the load Rload is short-circuited, and LED3 is used to indicate that the load Rload current is normal.

2. The black box processor circuit with load detection function according to claim 1, characterized in that: The preset voltage V2 outputted by the voltage stabilizing component satisfies the relationship: V2≈[(V3+V PN_Q5 )*(R14+R16)] / R16; wherein, V3 is the voltage stabilization value of the voltage stabilizing tube D3, V PN_Q5 is the PN junction on voltage of the triode Q5.

3. The black box processor circuit with load detection function according to claim 1, characterized in that: When the load current Rload is within the normal range of 0A~I nomal At time A, the voltage V collected by resistor R3 is designed to be... sensor_R3 < The PN junction forward voltage V of transistor Q1 PN_Q1 When transistor Q1 is cut off, LED1 does not light up; simultaneously, diode D1 is reverse biased, and the collector voltage V of Q1 is... c_Q1 < The PN junction forward voltage V of transistor Q3 PN_Q3 When Q3 is cut off, V1 provides operating current to LED3 after being current-limited by R2, and LED3 lights up. Because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, and V1 makes Q4 saturate and conduct through R1 and R6. The collector of Q4 outputs a low level, and LED2 does not light up.

4. The black box processor circuit with load detection function according to claim 1, characterized in that: When the load current Rload is in an abnormal range value I nomal A~I abnomal_1 At time A, the voltage V collected by resistor R3 is designed to be... sensor_R3 > The PN junction forward voltage V of transistor Q1 PN_Q1 Transistor Q1 operates in amplification mode, and the high-level output from the collector of Q1 illuminates LED1; simultaneously, the high-level output from the collector of Q1, through R10, causes Q3 to saturate and conduct, with its saturation voltage V. sat_Q3 < LED3's forward voltage V led3， LED3 is off; because the output voltage of the voltage regulator component V2 < V1, D2 is reverse biased, Q4 is saturated and conducting, and the collector of Q4 outputs a low level, so LED2 does not light up.

5. The black box processor circuit with load detection function according to claim 1, characterized in that: When the load Rload is short-circuited, the voltages of diodes D1 and D2 are clamped to V respectively. doide_D1 V doide_D2 Design V doide_D1 <V PN_Q4 V doide_D2 <V PN_Q3 V PN_Q4 The PN junction turn-on voltage of transistor Q4, V PN_Q3 When the PN junction of transistor Q3 is turned on, transistors Q3 and Q4 are turned off, and LED1 and LED2 are not lit. When transistor Q3 is turned off, V1 is limited by resistor R2, which lights up LED3.

6. The black box processor circuit with load detection function according to claim 1, characterized in that: The load Rload is an ambient light, and this small black box processor circuit is used for factory performance testing of ambient light products.

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