Circuit Interrupter On-the-fly Firmware Update via Memory Segmentation
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Solution Overview
Problem
Circuit interrupters often experience nuisance tripping due to normal operation of electrical devices or new devices being connected, leading to false detection of electrical faults and the need for frequent firmware updates to address these issues.
Innovation Solution
The system allows for dynamic on-the-fly firmware updates to be stored in a non-volatile memory while the circuit interrupter remains in a normal operating state, enabling continuous power delivery to downstream electrical loads without the need to disconnect them or switch to a safe mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit interrupter switches to safe mode to perform firmware updates, then the firmware can be updated, but the electrical circuit is interrupted and downstream loads lose power
Solution Approach 1:
The patent divides the firmware storage into two separate memory locations: non-volatile memory for persistent storage and volatile memory for active execution. This segmentation allows the system to store updated firmware in non-volatile memory while continuing to execute the old firmware from volatile memory, enabling updates without circuit interruption.
Solution Approach 2:
The system performs preliminary actions by storing the firmware update in non-volatile memory before actually executing it. The controller copies the updated firmware to non-volatile memory while the circuit remains operational, then switches to executing the updated firmware from volatile memory without interrupting power delivery to downstream loads.
2Reliability
If the circuit interrupter replaces the controller hardware to fix nuisance tripping, then the firmware issue is resolved, but the device complexity and downtime increase
Solution Approach 1:
The patent uses copying to transfer firmware from non-volatile memory to volatile memory. The controller copies the updated firmware instructions from non-volatile memory into volatile memory for execution, allowing firmware updates without hardware replacement or circuit interruption. This copying mechanism simplifies the update process while maintaining reliable fault detection.
3Adaptability or versatility
If the circuit interrupter uses dual-mode flash memory for firmware updates, then firmware can be updated, but the circuit must be opened to disconnect loads
Solution Approach 1:
The patent implements dynamic firmware updating by allowing the controller to switch between different memory modes. The system can dynamically copy firmware to non-volatile memory while operating normally, then dynamically switch to executing the updated firmware without opening the circuit. This dynamic approach maintains operation continuity while enabling firmware upgradability.
Data Source
AI summary
Devices and methods for on-the-fly updates of circuit breakers during operation, the circuit breaker including a processor, a first memory including a first and second slot, and a second memory. In response to initialization, the processor stores a copy of a most recent firmware from the first or second slot in the second memory and executes the most recent firmware at the second memory. The firmware in the first or second slot may be a first firmware, and in response to obtaining a second firmware, the processor stores a copy of the second firmware in the other of the first and second slot. In response to a second initialization, the processor stores a copy of the second firmware from the other of the first slot and second slot in the second memory to enable execution of the second firmware, the second firmware being the most recent firmware.