Insulation Transformer Circuit for External Control Status Diagnosis
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Solution Overview
Problem
Conventional systems for diagnosing the operation status of external control means, such as relay contacts operated by binary ON/OFF signals, require additional power source and insulation circuits for each contact, leading to increased manufacturing costs and complexity, and are limited in diagnosing distant contacts due to voltage drop issues.
Innovation Solution
A device using an insulation transformer with an intermediate tap, a signal generating circuit, and a detection circuit to measure current changes caused by the operation of external control means, allowing for accurate diagnosis of wire breaks and short circuits without separate power sources or monitoring circuits for each contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated power source circuit and monitoring circuit are provided for each contact to diagnose operation status, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (power supply, signal transmission, and operation status monitoring) into a single insulation transformer circuit. The primary winding serves as both the power source and the monitoring point, while the secondary winding provides insulation and power to the contact. By measuring current changes in the primary winding, the system diagnoses contact status without requiring separate monitoring circuits for each contact.
Solution Approach 2:
The insulation transformer is designed to perform multiple functions simultaneously: it provides electrical insulation between primary and secondary circuits, supplies power to the contact, and enables operation status diagnosis through current measurement. This multi-functional design eliminates the need for dedicated power sources and monitoring circuits for each contact.
2Reliability
If separate power source circuits are provided for each distant contact, then reliability is improved, but loss of energy increases due to voltage drop
Solution Approach 1:
The insulation transformer acts as an intermediary that provides local power generation at the contact location. By winding the primary coil around the secondary coil, the system creates a localized electromagnetic field that induces voltage in the secondary winding, compensating for voltage drops in long wires and enabling reliable operation and diagnosis of distant contacts.
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
Enables high-accuracy diagnosis of external control means operation status with a simple circuit construction, reducing manufacturing costs and eliminating the need for additional power sources and insulation means, while effectively diagnosing both near and distant contacts.
Implementation Method 1
an insulation transformer having an intermediate tap at a midpoint of its primary winding as insulation means
Data Source
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AI summary
Provided is an operation status diagnosing device for an external control means, which is enabled by a simple constitution to perform the transmission of the drive status of an external control means constituted of either a relay contact to be activated by an ON/OFF signal or an ON/OFF means made of a semiconductor, and the transmission of a signal indicating the occurrence of troubles such as disconnection or shorting of a wiring line and the transmission of an electric power by a common means, thereby to prevent the rise of a production cost due to the increase in a parts count or the complexity of a circuit constitution and to diagnose the transmission of the signal and the soundness of the circuit precisely. The operation status diagnosing device for the external control means is constituted to comprise a second switch circuit for turning ON/OFF an alternating voltage generating means output in response to the drive signal of the external control means, thereby to apply that output to an insulating transformer primary side, a first switch circuit serving as an external control means connected with an insulating transformer secondary side, so that it is turned ON/OFF by the second switch circuit, an external control means operation status detecting circuit connected with the insulating transformer secondary side, so that an electric current flows therethrough when the first switch circuit is ON, and a measuring means connected with the second switch circuit, for measuring the electric current to flow to the insulating transformer primary side.