Load Controller Parallel Semiconductor Relay Current Distribution
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Solution Overview
Problem
Conventional load controllers face issues such as the need for replacement when load current increases, cumbersome identification number setting for program selection, and inadequate simultaneous switching of parallel switches during abnormal conditions, leading to heat generation and resistance deterioration.
Innovation Solution
A load controller with a current detection unit and adjustment units that dynamically adjust the number of switches connected in series and parallel, and implement PWM control with phase shifting to manage current distribution and switch timing, ensuring no replacement is necessary and preventing abnormal heat and resistance degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the load current increases due to change or addition of load equipment, then the current handling capacity is improved, but the semiconductor relay needs a capacity for large current which requires replacement of the entire load driving device
Solution Approach 1:
The patent divides the single semiconductor relay into multiple semiconductor relays (first and second relays) that can be independently controlled. This segmentation allows the system to handle increased load current by activating additional relays without replacing the entire load driving device, thus resolving the contradiction between current handling capacity and device replaceability.
Solution Approach 2:
The patent implements dynamic control where the controller selectively turns on or off individual semiconductor relays based on the actual load current requirements. This dynamic adaptability allows the system to scale its current handling capacity flexibly without requiring physical replacement of the load driving device, addressing both improved power capacity and enhanced adaptability.
2Adaptability or versatility
If identification information is set in the socket to select necessary programs, then program selection capability is improved, but troublesome work of setting identification information in advance is required
Solution Approach 1:
The patent implements a self-service mechanism where the socket automatically detects the load type and selects the appropriate control program without requiring manual setting of identification information. The system performs self-identification and self-configuration, eliminating the troublesome setup work while maintaining program selection capability.
Solution Approach 2:
The patent uses feedback mechanisms where the socket receives information about the connected load and automatically adjusts its behavior by selecting the appropriate control program. This feedback-based automatic program selection improves adaptability while eliminating the need for manual identification setting, thus improving ease of operation.
3Power
If parallel switches are turned on and off simultaneously to drive the same load, then current distribution is improved, but abnormal heat generation and resistance deterioration occur due to non-simultaneous switching
Solution Approach 1:
The patent replaces mechanical simultaneous switching with electronic control using control signals. The controller generates coordinated control signals that account for variations in on-resistance and pattern resistance, enabling precise timing control of parallel switches. This electronic substitution ensures simultaneous effective switching while preventing abnormal heat generation, thus maintaining both good current distribution and high reliability.
Solution Approach 2:
The patent introduces a controller as an intermediary that coordinates the switching of parallel semiconductor relays. This intermediary device monitors and adjusts the switching timing of individual relays to compensate for manufacturing variations, ensuring they effectively switch simultaneously. This intermediary control maintains reliable current distribution while preventing heat generation issues.
4Power
If a plurality of parallel switches is used to reduce current flowing to each switch, then current per switch is reduced, but all switches cannot be turned off simultaneously due to variations in on-resistance and pattern resistance
Solution Approach 1:
The patent introduces a controller as an intermediary that coordinates the switching of parallel semiconductor relays. This intermediary device monitors and adjusts the switching timing of individual relays to compensate for manufacturing variations, ensuring they effectively switch simultaneously. This intermediary control maintains reliable current distribution while preventing heat generation issues.
Solution Approach 2:
The patent dynamically adjusts switching parameters (timing, duration) of individual parallel relays based on their specific characteristics. By changing these parameters, the system compensates for manufacturing variations in on-resistance and pattern resistance, achieving effective simultaneous switching while maintaining reduced current per switch, thus resolving the contradiction between current reduction and switching precision.
Data Source
AI summary
A plurality of semiconductor relays is provided between a power source and loads. The semiconductor relays have a function of a current detection for detecting a current passing through themselves. The loads are connected to output terminals respectively. A switching unit arbitrarily selects and switches a connecting destination of the semiconductor relays from among the plurality of output terminals. A microcomputer controls the switching unit on the basis of the detection results of a current flowing through the semiconductor relays, and adjusts the number of the semiconductor relays connected to the same load and connected to each other in parallel.