Current Output Driver Supply Voltage Optimization
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Solution Overview
Problem
Existing input/output modules experience significant power loss due to inefficient supply voltage regulation in current output drivers, which is not effectively addressed by continuous voltage adjustment methods.
Innovation Solution
A circuit comprising a microcontroller, a digital/analog converter, and a DC/DC converter that dynamically adjusts the supply voltage based on measured output current and voltage values, using a control signal to optimize power delivery and reduce losses by setting the supply voltage according to specific current and voltage ranges, and incorporating an offset voltage that can be adapted over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the supply voltage is continuously regulated as a function of the output voltage, then the power loss decreases, but the device complexity increases due to additional control circuits
Solution Approach 1:
The system uses the existing output voltage signal that is already being measured for other purposes to also control the supply voltage regulation. This self-service approach allows the system to regulate power without adding separate sensing circuits, thereby reducing complexity while maintaining energy efficiency.
Solution Approach 2:
The microcontroller performs multiple functions: it controls the current output driver, reads the output voltage, determines supply voltage values, and controls the DC/DC converter. By making the microcontroller universal and multi-functional, the system avoids adding dedicated control circuits, thus reducing overall device complexity while achieving continuous power loss reduction.
2Loss of energy
If the supply voltage is reduced when low output voltage flows, then the power loss decreases, but the measurement precision may deteriorate due to lower signal levels
Solution Approach 1:
The system determines an appropriate supply voltage value before actually applying it to the current output driver. This preliminary determination allows the system to select optimal voltage levels that balance power efficiency with measurement precision requirements, ensuring that measurements are taken at suitable voltage levels before the actual operation occurs.
Solution Approach 2:
The supply voltage is dynamically adjusted based on the actual operating conditions and output voltage levels. The microcontroller continuously monitors the output voltage and adaptively selects supply voltage values, allowing the system to optimize between power loss reduction and measurement precision in real-time based on the current operating state.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces power loss in current output drivers by optimizing supply voltage settings, ensuring efficient power delivery across varying load conditions and minimizing energy wastage, while also accommodating changes in resistance over time.
Implementation Method 1
a first DC/DC converter (200) which generates a first supply voltage (V1) for supplying the current output driver (430)
Data Source
AI summary
A circuit for an I/O module, the circuit having a communication unit for receiving process data, which is connectable to a bus for communication purposes, a microcontroller which is connected to the communication unit, a load, a digital/analog converter, which includes a current output driver for outputting an output current to the load, and a first DC/DC converter. The microcontroller is connected to the digital/analog converter via a digital interface and is configured to set the output current of the digital/analog converter via the digital interface based on the received process data. The microcontroller is configured to output a control signal to a first DC/DC converter via the control interface for setting the first supply voltage based on the output current and the digital voltage value.