Load Circuit Current Profiles for Power Supply Capacity Limits
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Solution Overview
Problem
Existing methods for protecting load circuits in technical systems fail to account for the capacity of the power supply unit, leading to incorrect tripping parameters and potential system failures due to inappropriate sizing of fuses, resulting in unnecessary shutdowns or damage from current overloads.
Innovation Solution
A method for monitoring and controlling current distribution in load circuits by measuring and deriving significant current profiles and tolerance ranges during a learning phase, using a control unit to manage current draw based on the power supply unit's capacity, reducing or switching off current when limits are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic fuses with adjustable tripping parameters are used to protect load circuits, then the response speed and protection accuracy improve, but the device complexity and cost increase
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the tripping current parameter of electronic fuses based on the actual power supply unit capacity and load characteristics. During a learning phase, the system measures current waveforms and determines significant current profiles, then uses these profiles to adaptively set tripping parameters rather than using fixed values, thereby achieving accurate protection without requiring overly complex predetermined configurations
Solution Approach 2:
The system implements feedback by continuously monitoring the current draw of each load circuit and comparing it against the determined significant current profile and power supply capacity. When a fault condition is detected, the control unit receives feedback about the current state and automatically adjusts the tripping parameters or activates the switching unit to disconnect the load, creating a closed-loop protection system that responds dynamically to actual conditions
2Ease of operation
If fixed tripping parameters are set for electronic fuses during planning phase, then the ease of operation improves, but the adaptability to actual system conditions deteriorates
Solution Approach 1:
The system applies preliminary action by performing a learning phase during initial system operation where current waveforms are measured and significant current profiles are determined for each load circuit. This preliminary characterization of load behavior occurs automatically without requiring manual configuration, after which the system uses these pre-determined profiles to make real-time protection decisions, combining automated adaptation with operational simplicity
Solution Approach 2:
The system implements self-service by automatically determining its own protection parameters through the learning phase. The control unit autonomously analyzes current waveforms, identifies significant current profiles, and configures tripping parameters based on the actual power supply capacity and load characteristics without requiring external intervention or manual tuning, thereby achieving both ease of operation and high adaptability
3Ease of manufacture
If the power supply unit capacity is not considered in fuse sizing, then the ease of manufacture improves, but the reliability of the overall system deteriorates
Solution Approach 1:
The system applies universality by creating a unified control approach that simultaneously manages multiple load circuits with different characteristics while considering the overall power supply unit capacity. The control unit uses a single significant current profile determination method that works across all load circuits and integrates the power supply capacity constraint into a comprehensive protection strategy, making the system reliable without requiring complex individual sizing calculations for each circuit
Data Source
Figure 1~2
AI summary
The invention relates to a method for monitoring and controlling current distribution in load circuits (L1, L2, L3) of a control system for a technical plant. A predetermined, usually constant, output voltage (UA) is provided by at least one switched-mode power supply unit (NG) and distributed to the load circuits (L1, L2, L3) of the plant to supply power to the load units. Furthermore, at least a plurality of the load circuits (L1, L2, L3) are protected by a switching unit (S1, S2, S3), which is controlled by a control unit (SE). During a learning phase, a current waveform (il, i2, i3) of the current drawn by the respective load circuit (L1, L2, L3) is measured (101) in at least one load circuit (L1, L2, L3) protected by a switching unit (S1, S2, S3).From the current waveform (il, i2, i3) measured for each load circuit (L1, L2, L3), a significant current profile with an associated tolerance range is derived and assigned to the respective load circuit (102). During the ongoing operation of the system, the control unit (SE) continuously monitors the current waveforms (il, i2, i3) measured for the load circuits (L1, L2, L3) (103) and checks whether the clocked power supply unit (NG) is at least reaching a performance limit (104).When the power supply unit (NG) reaches its capacity limit, the control unit (SE) reduces and/or switches off (105) the current drawn by the respective load circuits (L1, L2, L3) by activating the respective switching unit (S1, S2, S3) in those load circuits (L1, L2, L3) where a current profile (il, i2, i3) currently measured for the respective load circuit (L1, L2, L3) exceeds an upper limit of the tolerance range of the significant current profile assigned to the respective load circuit (L1, L2, L3).