Backup Battery Voltage Drop Detection via Data Corruption
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Solution Overview
Problem
Existing voltage drop detection systems for backup batteries in numerical controllers fail to accurately detect voltage drops when the main power supply is off due to variations in battery voltage depending on load conditions.
Innovation Solution
A voltage drop detection system that includes a second volatile memory connected in parallel with the first volatile memory, a data writing unit, a data corruption detection unit, and a voltage drop detection unit, which uses a step-down circuit to lower the voltage supplied to the second volatile memory during the battery warranty period, allowing for accurate detection of voltage drops when the main power supply is off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If voltage monitoring is performed using existing methods, then battery voltage can be monitored when main power supply is on, but accurate detection of voltage drops when main power supply is off is impossible due to battery voltage variations under different load conditions
Solution Approach 1:
The system segments the detection function by separating the detection memory from the main volatile memory. The detection memory is specifically dedicated to voltage drop detection operations, allowing independent optimization of detection accuracy without affecting normal system operation. This segmentation enables the system to monitor battery voltage independently when main power is off, resolving the contradiction between measurement precision and reliability under different power states.
Solution Approach 2:
A step-down circuit is introduced as an intermediary component between the battery and the detection memory. This intermediary circuit provides a controlled voltage environment that enables accurate detection of voltage drops without being affected by the variable load conditions that affect direct battery voltage measurements. The step-down circuit acts as a mediator that stabilizes the detection process while allowing early detection of battery degradation.
2Measurement precision
If a step-down circuit is used to lower voltage to detection memory, then accurate voltage drop detection when main power is off is enabled, but device complexity increases
Solution Approach 1:
The step-down circuit is designed with multi-functionality to justify its inclusion in the system. Beyond voltage reduction for detection memory, the circuit supports early battery degradation detection, provides a stable reference for voltage threshold comparisons, and enables detection operations without interfering with main system operations. This universal application reduces the relative complexity burden by providing multiple valuable functions from a single added component.
3Reliability
If detection memory is monitored continuously, then early battery degradation can be detected, but energy consumption from battery increases
Solution Approach 1:
The system employs periodic action by only activating the detection memory and performing detection operations when the main power supply is turned off. During normal operation when main power is on, the detection memory is not actively consuming battery energy. This periodic monitoring approach allows early degradation detection capability while minimizing battery energy consumption to only the essential moments when main power is unavailable and detection is most critical.
Solution Approach 2:
The detection function is extracted as a separate, independent operation from the main system operations. By taking out the detection memory and its monitoring function as a distinct subsystem that operates independently when main power is off, the system achieves early degradation detection without requiring continuous energy consumption. The extraction allows the detection function to be activated only when necessary, reducing overall battery energy usage while maintaining detection capability.
Data Source
AI summary
An object is to provide a voltage drop detection system which can accurately detect a drop in the voltage of a backup battery when a main power supply is off. A voltage drop detection system detects a drop in the voltage of a battery that supplies power to a first volatile memory when a main power supply is off, and the voltage drop detection system includes: a second volatile memory which is connected for the battery in parallel with the first volatile memory; a data writing unit which writes data in the second volatile memory when the main power supply is on; a data corruption detection unit which supplies, when the main power supply is off, power from the battery to the first volatile memory and the second volatile memory and which thereafter detects the corruption of the data written in the second volatile memory when the main power supply is on; and a voltage drop detection unit which detects the drop in the voltage of the battery based on the detection of the corruption of the data when the main power supply is on.