Electronic Switch Controller Using Multi-Segment PWM Curve
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Solution Overview
Problem
Existing electronic switches are complex in design, difficult to wire, bulky, and incapable of controlling electric devices at an accurate working point due to their single-segment linear control curve and numerous components, leading to short low-speed travel and poor connection matching with other devices.
Innovation Solution
An electronic switch controller method that integrates a voltage-stabilized power supply, driving circuit, and processor to read duty cycle parameters, calculate a new duty cycle, and adjust PWM signals for motor control, using multi-segment curve control to improve low-speed travel and facilitate accurate operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-segment linear control curve is used for PWM output, then the circuit design is simplified, but the low-speed travel is shortened and accurate working point control is lost
Solution Approach 1:
The control curve is divided into multiple segments instead of using a single linear segment. Each segment corresponds to a different travel range of the electronic switch, with different slope values. This segmentation allows the system to provide different control characteristics for different operating ranges, thereby extending low-speed travel while maintaining manageable circuit complexity through standardized segment processing.
Solution Approach 2:
The control curve transitions from a static single-segment linear design to a dynamic multi-segment curve that can adapt to different operating conditions. The system dynamically selects appropriate segment combinations based on the current switch travel position, enabling the control characteristics to change dynamically and extend the effective low-speed travel range.
2Manufacturing precision
If multiple electronic components are used for voltage stabilization and PWM driving, then the control precision is improved, but the PCBA size increases and production cost rises
Solution Approach 1:
The patent merges the voltage-stabilized power supply, processor, and PWM driving circuit into an integrated controller unit. This consolidation maintains the functional capabilities and control precision of separate components while reducing the overall PCBA area and simplifying the circuit design. The integrated design eliminates the need for multiple discrete components and their associated connections.
Solution Approach 2:
The integrated controller performs multiple functions simultaneously: voltage stabilization, signal processing, and PWM generation. This multi-functionality replaces what would traditionally require separate dedicated components, thereby reducing PCBA size while maintaining or improving control precision through coordinated operation of the integrated functions.
3Reliability
If separate voltage-stabilized power supply and PWM driving circuit are used, then the reliability is improved, but the device complexity and wiring difficulty increase
Solution Approach 1:
The patent combines the voltage-stabilized power supply and PWM driving circuit into a single integrated controller module. This merging maintains the reliability benefits of having dedicated voltage stabilization and driving functions while reducing the overall device complexity and wiring requirements. The integrated design provides a single point of control that simplifies the system architecture.
4Ease of manufacture
If a single-segment linear control curve is used, then the PCB wiring is simplified, but the accurate working point control is lost
Solution Approach 1:
The control curve is segmented into multiple linear sections, each with different slope values optimized for specific travel ranges. This segmentation enables accurate working point control across the entire travel range, particularly extending accurate control into the low-speed range. The PCB wiring remains relatively simple as the multi-segment curve is implemented through software or lookup tables in the processor rather than requiring complex analog circuitry.
Data Source
AI summary
An electronic switch control method is disclosed. The method comprises receiving the current working parameters of the electronic switch, then reading duty cycle parameters matching with the current working parameters; conducting a linear calculation with the duty cycle parameters and the working parameters to obtain a new duty cycle; adjusting the current control signal to obtain a PWM signal having the new duty cycle; and controlling the rotation speed of the motor in a load with the PWM signal. By reducing the volume of an electronic switch and achieving a long low-speed travel, the disclosure enables the user to work at an accurate working point with an electronic device.