Integrated Electronic Load Module for PCB Testing
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Solution Overview
Problem
Conventional electronic load setups for testing power supply systems on printed circuit boards (PCBs) face issues such as high ohmic losses due to long leads, parasitic inductances and capacitances, and the need for expensive and bulky environmental test chambers, which hinder precise slew-rate measurements and realistic temperature simulations.
Innovation Solution
An electronic load module with a digital control circuit connected to a power controller via a data bus, an active load that can sink a defined current and generate ambient temperature, eliminating the need for external leads and environmental test chambers by integrating within the PCB and using existing heat sinks for realistic temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional electronic load equipment is used with long leads to connect to the PCB, then the electronic load can be provided externally, but parasitic inductances and capacitances are introduced that hinder precise slew-rate measurements
Solution Approach 1:
The electronic load module is merged directly onto the PCB by integrating the active load circuitry and digital control circuit onto the same board where the power supply system under test resides. This eliminates the need for external connections via long leads, thereby removing parasitic inductances and capacitances that would otherwise degrade slew-rate measurement precision.
Solution Approach 2:
A data bus connector serves as an intermediary communication interface between the power controller on the PCB and the digital control circuit of the electronic load module. This allows precise digital control of the active load while maintaining direct integration on the PCB, avoiding the need for external connections and their associated parasitic effects.
2Temperature
If an environmental test chamber is used to test temperature effects on the power supply system, then temperature control is provided, but the chamber is expensive and bulky
Solution Approach 1:
The active load circuit on the PCB serves a dual function: it acts as the electronic load for testing the power supply system while simultaneously serving as a heating element to generate ambient temperature. This self-service approach eliminates the need for external environmental test chambers, reducing device complexity and cost while maintaining temperature control capability.
Solution Approach 2:
The active load circuit is designed with multi-functionality, serving both as the electrical load for power supply testing and as a temperature control mechanism. This universal component replaces the need for separate temperature control equipment, making the testing system more compact and cost-effective.
3Power
If the active load is controlled to sink defined current, then precise electrical loading is achieved, but heat generation must be managed to control ambient temperature
Solution Approach 1:
A feedback control mechanism is implemented where the digital control circuit monitors the current sinking operation of the active load and adjusts its operation to control the heat generation. This feedback system ensures that the active load sinks the required defined current for electrical testing while simultaneously maintaining control over the ambient temperature it generates, resolving the contradiction between power control and temperature management.
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 allows for precise and realistic testing of power supply systems without the need for external test chambers, reducing parasitic effects and enabling accurate slew-rate measurements and temperature simulations, thus improving the efficiency and cost-effectiveness of PCB testing.
Implementation Method 1
an active load operatively connected to and controlled by the digital control circuit and configured to sink a defined current from the device under test
Implementation Method 2
The active load of the electronic load module is configured to be controlled by the digital control circuit to generate and maintain an ambient temperature of the connectable device under test
Data Source
AI summary
The present invention relates to an electronic load module and to a method and a system therefor. The method comprises receiving control data (301) from a connectable power controller via a data bus connector (202), and controlling (302) an active load (203) based on the received control data to sink a defined current from a connectable device under test via a first input (204). The method further comprises controlling (303) the activate load (203) based on the received control data by means of a digital control circuit (201) and the connectable power controller to generate and maintain an ambient temperature of the device under test.