Output Module Calibration for Fast Complex Load Testing
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Solution Overview
Problem
Testing an output module connected to a complex load is time-consuming and complex, as it requires monitoring and comparing voltage levels over a complete discharge period, which can be lengthy, especially for capacitive loads.
Innovation Solution
The output module includes a calibration unit that performs a two-stage method: a calibration stage to store a 'fingerprint' of the load's discharge behavior and a regular test stage that uses this data to conduct shorter tests by disconnecting the load and monitoring significant changes, allowing for faster and more efficient functionality checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complete discharge period monitoring is used for testing output module connected to complex load, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The system performs a calibration stage before regular testing to obtain and store the discharge curve characteristics of the complex load. This preliminary action creates a reference fingerprint that enables faster subsequent testing without compromising measurement precision, as the stored characteristics allow the system to determine test periods and evaluate functionality based on significant changes rather than complete discharge monitoring.
Solution Approach 2:
The system creates a digital copy (fingerprint) of the load's discharge behavior by storing voltage level data at different times during a complete discharge cycle. This copied information is then used during regular tests to evaluate functionality by comparing against the stored fingerprint, eliminating the need to perform complete discharge cycles repeatedly and thus reducing testing time while maintaining precision.
2Reliability
If complete discharge monitoring is performed during regular tests, then reliability of functionality test is improved, but productivity decreases
Solution Approach 1:
The calibration stage performed before regular testing establishes the complete discharge curve and stores it as a reference fingerprint. This preliminary action ensures that the reliability of functionality testing is maintained by having accurate reference data, while regular tests can then proceed more quickly by comparing against this pre-established reference rather than performing complete discharges each time.
Solution Approach 2:
During regular tests, the system performs only partial monitoring by measuring voltage levels at specific predetermined times and comparing these partial measurements against the complete discharge fingerprint stored from calibration. This partial action approach maintains reliability by using the complete reference data while improving productivity by avoiding the time-consuming complete discharge process during each regular test.
3Measurement precision
If complex load discharge characteristics are fully monitored, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The system extracts only the essential characteristics of the complex load's discharge behavior by measuring and storing voltage levels at specific predetermined times during the discharge cycle. Rather than continuously monitoring all aspects of the discharge, the system extracts key data points that form the fingerprint, reducing the complexity of the testing system while maintaining sufficient measurement precision for functionality evaluation.
Solution Approach 2:
The system creates a simplified digital representation (fingerprint) of the complex discharge characteristics by copying only the essential voltage-time data points. This copied fingerprint captures the essential discharge behavior without requiring the system to handle or process the full complexity of continuous discharge monitoring, thus reducing device complexity while preserving measurement precision for functionality testing.
Data Source
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AI summary
An output module (200) includes multiple outputs (202), each output having switches (204, 208), wherein the switches (204, 208) are configured such that a load (212) is connectable between the switches (204, 208), and a calibration unit (220) configured to disconnect the load (212) from the switches (204, 208) for a calibration period, monitor a behavior of the load (212) while disconnected, and store samples of the behavior of the load (212). Further aspects of the present disclosure relate to a control system (100) and a method (300) for testing an output module (200) connected to a complex load (212).