Load Controller Circuit Using PWM Power and Communication Lines
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Solution Overview
Problem
Controllers for actuating loads in vehicles are complex and costly due to multiple supply and communication lines, leading to increased weight and space requirements in cable harnesses.
Innovation Solution
A controller design that uses a controllable switching element between two supply connections, eliminating the need for a separate ground connection and utilizing pulse width modulation, with an energy storage element for power during active phases and a control signal transceiver for communication via supply lines, reducing the need for special communication lines and saving weight and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple supply lines and communication lines are provided for the controller, then the controller can perform its functions reliably, but the device complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into a single connection line. The first connection line serves simultaneously as a supply voltage line, communication line, and ground reference by using pulse width modulation signals that switch between high and low states. This eliminates the need for separate supply lines, communication lines, and ground connections, thereby reducing device complexity while maintaining reliable controller operation.
Solution Approach 2:
The first connection line is designed to perform multiple functions: it provides supply voltage to the controller, carries communication signals bidirectionally, and serves as a ground reference during low states. The control signal transceiver enables bidirectional communication on this multi-functional line, allowing the same physical connection to handle power delivery, data transmission, and reference potential.
2Reliability
If multiple supply lines and communication lines are provided for the controller, then the controller can perform its functions reliably, but the weight and space requirements increase
Solution Approach 1:
The patent merges multiple cable functions into a single cable connection. Instead of requiring separate cables for supply voltage, ground, and bidirectional communication, the invention uses one cable that carries pulsed signals serving all these purposes simultaneously. This significantly reduces the total cable length and cross-section required, thereby reducing cable harness weight and space occupation in the vehicle.
3Reliability
If multiple supply lines and communication lines are provided for the controller, then the controller can perform its functions reliably, but the costs increase
Solution Approach 1:
The patent combines multiple signal and power lines into a single connection line, which reduces the bill of materials (fewer connectors, less cable, fewer pins) and simplifies assembly processes. The control signal transceiver and switching element, while adding some electronic components, eliminate the need for multiple separate connection paths, resulting in net cost reduction through simplified manufacturing and reduced material usage.
4Speed
If the controller is continuously connected to the supply voltage, then it can respond immediately to events, but the energy consumption increases
Solution Approach 1:
The patent uses periodic pulse width modulation signals to connect the controller to the supply voltage only during active phases. The switching element periodically connects and disconnects the controller from the supply voltage based on the PWM signal state. During low states, the controller operates from internal energy storage, reducing energy consumption while maintaining the ability to respond quickly when pulses are active.
Solution Approach 2:
The patent dynamically controls the connection between the controller and supply voltage using a switching element that responds to PWM signals. The connection is made active only when needed (during high states of the PWM signal) and inactive during other periods (low states). This dynamic switching allows the controller to balance between immediate responsiveness and energy conservation by being connected only during active phases.
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 design reduces complexity and cost by eliminating unnecessary connections, providing efficient power management and communication, while protecting components from overvoltage and detecting overcurrents, thus optimizing resource usage in vehicle systems.
Implementation Method 1
the controller is not continuously connected to the supply voltage, but rather via the switching element, which is controlled with pulse width modulation
Implementation Method 2
The energy for supplying the controller is provided in the active phases of the load by the energy storage element in the second voltage supply unit, which energy storage element is charged in the switching pauses
Implementation Method 3
having a diode which is connected by its anode to the connection point of the coil and the controllable switching element and by its cathode to the supply connection of the first voltage supply unit
Data Source
AI summary
A controller for actuating a load includes first and second supply connections. The first supply connection is connected to a high supply voltage potential or the second supply connection is connected to a low supply voltage potential. A controllable switching element is connected between the supply connections. A control unit is connected to the controllable switching element. A control signal transceiver is connected to the first supply connection and to the control unit. A first voltage supply unit is connected to the control signal transceiver. A second voltage supply unit with an energy storage element is connected to the control unit. A coil is connected between the first supply connection and the controllable switching element. A diode is connected to a connection point of the coil and the controllable switching element and to supply connections of the first and second voltage supply units.