IO Power Supply Load Testing Without Interrupting Operation
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Solution Overview
Problem
Industrial automation systems face challenges in testing the current output of IO power supply modules without disrupting ongoing operations, particularly in scenarios where powering the load is undesirable or impractical, such as with redundant power supplies or critical systems like fire suppressants.
Innovation Solution
The implementation of a testing circuitry within IO power supply modules that allows for online current load testing by using a switch to connect the voltage supply to resistors, enabling the calculation of current output without interrupting the load, utilizing a pulsed voltage signal and timing circuitry to manage test duration and prevent interference with primary operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the load is powered on to test the IO power module current output, then the current measurement accuracy is improved, but the operational continuity of the system deteriorates
Solution Approach 1:
The patent introduces a current sense resistor as an intermediary element to measure the current output of the IO power module. Instead of directly powering the load for measurement, the sense resistor is placed in series with the load, and a voltage measurement across this resistor provides indirect current measurement. This allows the load to remain powered and operational while still enabling accurate current verification through voltage sensing.
2Measurement precision
If the load is powered down for testing, then the testing accuracy is improved, but the productivity of the industrial automation system deteriorates
Solution Approach 1:
The patent enables continuous operation of the load during testing by maintaining power supply to the load throughout the measurement process. The current sense resistor allows for non-intrusive current measurement without requiring the load to be disconnected or powered down, thus ensuring that manufacturing and automation tasks continue uninterrupted while testing is performed.
3Reliability
If a redundant power supply configuration is used, then the reliability of the system is improved, but the ability to perform online testing deteriorates
Solution Approach 1:
In redundant power supply configurations, the patent places a current sense resistor in series with the load for each power supply module. This intermediary element enables independent current measurement for each module without requiring the load to be disconnected or the system configuration to be changed. The voltage across each sense resistor can be measured to verify the current output capability of individual modules while they remain in their redundant configuration.
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 reliable and non-disruptive testing of IO power supply modules, ensuring they meet rated current outputs without affecting ongoing operations, thereby improving detection of faulty components and reducing the risk of undetected issues in critical systems.
Implementation Method 1
determining an amount of current present in the output current based on a resistance value associated with the current measurement circuit and the voltage
Data Source
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AI summary
Embodiments of this present disclosure include an input/output (IO) power supply module coupled to a load. The IO power supply module may include testing circuitry that couples to a voltage supply of the IO power supply module. The testing circuitry may perform an online load current test to verify performance of IO power supply module. To do so, the testing circuitry may include a current measurement circuit coupled to a switch. The current measurement circuit may receive a current via the switch while closed to determine whether the output current generated by the voltage supply is equal to a rated output current.