Controller Circuit Self-Validation for Internal Fault Detection

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Solution Overview

Problem

Existing transport refrigeration unit (TRU) control systems face challenges in identifying malfunctions and disconnections within their circuitry, necessitating complex manual troubleshooting due to the removal of service test points for cost and space constraints.

Innovation Solution

A self-validation system for TRU controller circuits using internal sensors to monitor voltage and current, comparing these values against expected ranges to identify fault conditions, and generating alerts for technician review.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If external validation circuits are added to validate controller internal circuits, then validation capability is improved, but device complexity increases

Engineering Contradiction:
Improvevalidation capabilityVSAvoidcircuit complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the validation function into the existing controller circuitry by integrating a validation circuit within the controller itself. This allows the controller to validate its own internal circuits (CPU, memory, bus) without requiring separate external validation hardware, thereby improving validation capability while minimizing the increase in device complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The validation circuit is designed to perform multiple validation functions across different controller components (CPU instructions, memory access, bus transactions) using a unified validation mechanism. This multi-functional approach allows a single validation circuit to comprehensively validate various aspects of controller operation, improving validation capability without proportionally increasing complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If comprehensive validation of all controller internal circuits is implemented, then reliability is improved, but validation time increases

Engineering Contradiction:
Improvevalidation coverageVSAvoidvalidation time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The validation circuit performs validation actions automatically and continuously during normal controller operation rather than requiring separate validation phases. Validation occurs in advance of potential failures by monitoring circuit behavior in real-time, which improves reliability coverage without significantly increasing validation time as the validation is interleaved with operational tasks.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The validation circuit operates continuously alongside the controller's normal functions, maintaining validation coverage without interrupting controller operation. This continuous validation approach ensures that all controller internal circuits are constantly monitored and validated while performing useful work, improving reliability without the time penalty of batch validation processes.

Inventive Principle:
Principle #20Continuity of useful action

Data Source

PatentEP3853622B1Self validation of controller internal circuits
Publication Date: 2026.05.13 CARRIER CORP
  • EP3853622B1 patent drawingFigure 1
  • EP3853622B1 patent drawingFigure 2
  • EP3853622B1 patent drawingFigure 3

AI summary

Systems and methods for testing circuit operations are provided. Aspects include a circuit comprising a power source, a switching element, and a load. A sensing element is arranged between the switching element and the load and the sensing element is communicatively coupled to a microcontroller, wherein the microcontroller is configured to perform a diagnostic operation for the circuit comprising obtaining, from the sensing element, first sensor data associated with the load responsive to operating the switching element, wherein the first sensor data comprises electrical values associated with the load, obtaining, from the sensing element, second sensor data associated with an output of the switching element, wherein the second sensor data comprises electrical values associated with the output of the switching element, and analyzing the first sensor data and the second sensor data to determine a fault condition for the circuit.