IO Power Supply Module Online Load Testing Without Load Interruption
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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, especially in scenarios where powering the load is undesirable or impractical, such as with redundant power supplies or fire suppressant systems.
Innovation Solution
The implementation of a testing circuitry within IO power supply modules that allows 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's power supply, utilizing a pulsed voltage signal and timing circuitry to ensure minimal disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the load is powered on to test the current output of the IO power module, then the current levels can be verified to meet the current rating, but the load operation is interrupted and manufacturing tasks are disrupted
Solution Approach 1:
The patent introduces a test circuit as an intermediary component that includes a switch, timing circuitry, and current measurement circuitry. This test circuit is coupled between the IO power module and the load, allowing current measurement without requiring the load to be powered on. The switch acts as a mediator that can be closed temporarily to enable current flow through the measurement circuitry while the load remains off, thus verifying current output without disrupting manufacturing tasks.
2Productivity
If the load is kept off for routine testing, then manufacturing tasks continue uninterrupted, but the current output of the IO power module cannot be verified
Solution Approach 1:
The patent segments the current measurement function from the load operation by introducing a separate test circuit with its own switch and measurement components. This segmentation allows the IO power module's current output to be measured independently of the load's operational state. The test circuit can be activated while the load remains off, enabling verification of current ratings without requiring load operation, thus maintaining manufacturing productivity while achieving measurement objectives.
3Measurement precision
If a switch is closed to enable current measurement, then the current output can be measured, but the switch must be opened quickly to avoid affecting load operation
Solution Approach 1:
The patent employs periodic or pulsed action through timing circuitry that controls the switch closure duration. The timing circuitry is configured to close the switch only for a brief, predetermined interval sufficient to capture the current measurement, then automatically opens the switch. This periodic activation allows the measurement to be taken quickly without sustained switch closure that would affect load operation, thus achieving precise current measurement while minimizing time loss and avoiding disruption to manufacturing tasks.
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 online validation of IO power supply modules' current output without affecting the load's operation, reducing the likelihood of undetected faulty power supplies and improving maintenance efficiency by allowing testing without turning the load on or off.
Implementation Method 1
The current measurement circuit may receive the output current from the voltage supply while the switch is closed. The control system receives an indication of a voltage across the current measurement circuit while the switch is closed from a sensing circuit, that determines 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
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.