Modular Controller Segmentation for PCB Redesign Reduction
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Solution Overview
Problem
Existing electrical system controllers require extensive retracing and requalification of printed wiring boards when upgrading or adapting to devices with different power and control requirements, leading to inefficiencies and increased design complexity.
Innovation Solution
A modular controller design featuring a generic motherboard with pin seats connected to signal and power traces, allowing for the abstraction of device-specific sections onto daughterboards, enabling the same motherboard to support multiple electrical devices with varying requirements without extensive redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If application-specific circuitry is implemented using printed wiring boards for each controlled device, then control precision for each device is improved, but device complexity and design time increase when adapting to different electrical devices
Solution Approach 1:
The controller is divided into a generic motherboard and detachable device-specific modules. The motherboard contains common circuitry that can be shared across multiple devices, while specific control functions are separated into interchangeable modules. This segmentation allows the generic motherboard to maintain control precision through standardized interfaces while reducing overall complexity by reusing common components across different device configurations.
Solution Approach 2:
The generic motherboard is designed with universal interfaces and standardized connection points that can accommodate multiple different electrical devices. By implementing universal mounting structures and standardized signal interfaces, the same motherboard can support various devices without requiring complete redesign, thereby reducing device complexity while maintaining the ability to provide precise control through device-specific modules.
2Adaptability or versatility
If printed wiring boards are customized for each electrical device, then adaptability to specific device requirements is improved, but manufacturing time and cost increase
Solution Approach 1:
The controller architecture separates the generic motherboard from device-specific functional modules. The generic motherboard can be manufactured in bulk using standardized processes, improving manufacturing efficiency. Device-specific modules are designed as separate units that can be independently manufactured and then assembled to the generic motherboard, maintaining adaptability to specific device requirements while avoiding the need to customize entire printed wiring boards for each device variant.
Solution Approach 2:
The generic motherboard is pre-configured with standardized interfaces, mounting structures, and common circuitry before device-specific modules are attached. This preliminary preparation allows for efficient assembly processes where device-specific modules can be quickly mounted and configured without requiring extensive custom wiring or redesign, thereby improving manufacturing efficiency while maintaining device adaptability.
3Adaptability or versatility
If retracing and rerouting of printed circuit boards is performed for device upgrades, then adaptability to new devices is improved, but loss of time and increased design complexity occur
Solution Approach 1:
The controller is segmented into a generic motherboard and interchangeable device-specific modules. When upgrading to support a new electrical device, only the device-specific module needs to be replaced or reconfigured, while the generic motherboard remains unchanged. This segmentation eliminates the need for time-consuming retracing and rerouting of the entire printed circuit board, maintaining upgrade adaptability while significantly reducing design time.
Solution Approach 2:
The generic motherboard incorporates universal interfaces and standardized connection protocols that can accommodate multiple different electrical devices. This universality allows the same motherboard design to support various devices without requiring redesign, rerouting, or retracing of circuit boards. Device upgrades are achieved by replacing or reconfiguring device-specific modules rather than modifying the entire controller, thereby maintaining adaptability while minimizing design time investment.
Data Source
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AI summary
A modular controller includes an enclosure (110) having an interior, a motherboard (108) with a signal trace (114) and a power trace (116) supported within the interior of the enclosure (110), and one or more control section. The control section includes one or more of an input power section, an electromagnetic interference section, a logic section, a control section, a output power section, and a signal section that is supported by the motherboard to selectively flow of electrical power through the power trace using a control signal carried by the signal trace. Electrical systems and methods of making modular controllers are also described.