Calibrated Current Sensing in Electronic Control Units
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Solution Overview
Problem
Traditional smart switches with current sensing have limited accuracy across a wide range of current levels, making it difficult to accurately measure and regulate power consumption and detect faults in loads, especially when handling diverse load components like incandescent and LED lights.
Innovation Solution
An electronic control unit with a current sensor system that performs calibrated measurements of current draw through switches, communicating these values to a controller to regulate power and detect faults, eliminating the need for dedicated current sensing in each switch and allowing for accurate power management across a broad range of currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional smart switches with current sensing are used, then current measurement is possible within a narrow range similar to nominal current, but measurement precision deteriorates across a wide range of current levels
Solution Approach 1:
The patent changes the measurement parameters by using multiple current sensing ranges (first range with first precision, second range with second precision) and dynamically selecting which range to use based on the actual current level. This allows the system to maintain high measurement precision across a wide current range by adapting the measurement parameters to match the operating conditions.
2Measurement precision
If individual switch current sensing is implemented, then current measurement for each switch is possible, but device complexity increases when multiple switch variants are needed
Solution Approach 1:
The patent makes a single smart switch model universal by equipping it with multiple current sensing ranges and the capability to automatically select the appropriate range. This eliminates the need for multiple switch variants designed for different current ranges, as one switch can now handle all current levels with appropriate precision by selecting the correct sensing range.
3Measurement precision
If multiple variants of smart switches are used for different current ranges, then accurate measurement for specific current levels is achieved, but ease of manufacture deteriorates due to increased production complexity
Solution Approach 1:
The patent simplifies manufacturing by producing a single universal smart switch model that incorporates multiple current sensing ranges. Instead of manufacturing and inventorying multiple specialized switch variants, the production line can focus on one design that automatically adapts to different current measurement requirements through software-controlled range selection.
Data Source
AI summary
Systems, devices, methods, and techniques are disclosed for performing calibrated measurements of current through switches in an electronic control unit. In one example, a device includes a current sensor system; a controller, operably connected to the current sensor system; and one or more switches, operably connected to the controller. The current sensor system is configured to receive a measurement of current conducted through at least one switch of the one or more switches. The current sensor system is further configured to perform a measurement of calibrated total current for the one or more switches. The current sensor system is further configured to determine a calibrated value of current for the at least one switch, based at least in part on a comparison of the measurement of current conducted through the at least one switch and the measurement of calibrated total current for the one or more switches.