Industrial Output Module Short-Circuit Detection via Voltage Divider
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Solution Overview
Problem
Existing industrial control apparatus output modules require a lengthy diagnosis period to verify switch functionality, leading to prolonged power supply interruptions and potential delays in emergency shutdowns due to the need to alternately turn off switches, which is inefficient and may compromise safety.
Innovation Solution
An output module with a voltage divider circuit that allows all switches to be turned off simultaneously, using a controller to detect short circuits based on a divided voltage, reducing the diagnosis period and enabling faster emergency shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If switches are turned off alternately for diagnosis, then short circuit detection is possible, but the diagnosis period becomes lengthy and power supply interruption is prolonged
Solution Approach 1:
The patent merges the diagnosis functions for multiple switches into a single simultaneous off-state test. Instead of turning off switches alternately (one at a time), all switches are turned off simultaneously and diagnosed together using a single voltage measurement, thereby eliminating the sequential time penalty while maintaining detection accuracy.
Solution Approach 2:
The patent introduces a voltage divider circuit as an intermediary measurement system. This circuit divides the voltage at the output node into a measurable range, allowing the controller to detect short circuits in switches during their off-state without direct contact or complex measurement arrangements, enabling rapid simultaneous diagnosis.
2Reliability
If switches are turned off alternately for diagnosis, then switch functionality can be verified, but emergency shutdown response is delayed
Solution Approach 1:
The patent combines the verification of all switch functionalities into a single simultaneous off-state measurement event. By diagnosing all switches together rather than sequentially, the system achieves complete verification in one rapid operation, enabling immediate emergency shutdown response without the time penalty of alternating diagnosis.
Solution Approach 2:
The patent performs preliminary diagnosis of all switches in their off-state before any emergency shutdown is required. The voltage divider circuit is pre-configured to measure all switches simultaneously, so when an emergency shutdown is needed, the system already has current status information and can respond immediately without delay for sequential verification.
3Loss of time
If multiple switches are diagnosed simultaneously, then diagnosis period is shortened, but detection precision may be compromised
Solution Approach 1:
The voltage divider circuit acts as a precision intermediary that accurately captures the voltage state at the output node during simultaneous switch off-state. This intermediary measurement system maintains detection precision by providing a scaled-down but proportional voltage signal that reflects the actual switch states, allowing simultaneous diagnosis without sacrificing measurement accuracy.
Solution Approach 2:
The patent replaces complex mechanical or sequential diagnostic mechanisms with an electrical voltage measurement system. The voltage divider circuit provides a non-contact, simultaneous electrical measurement of all switch states, eliminating the need for sequential mechanical testing while maintaining or improving detection precision through electrical signal proportionality.
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 configuration shortens the diagnosis period, allows for the use of loads with high responsiveness to power interruptions, ensuring prompt and safe shutdowns, and accurately identifies short circuits without erroneous turn-ons.
Implementation Method 1
a voltage divider circuit that divides a voltage between the power supply terminal and the output terminal to output a divided voltage
Data Source
AI summary
An output module of an industrial control apparatus includes an output circuit controlling an electrical connection between a power supply terminal and an output terminal and a controller controlling an operation of the output circuit. The output circuit includes multiple switches, which are connected in series between the power supply terminal and the output terminal, and a voltage divider circuit outputting a divided voltage. The controller controls on/off states of the switches, and detects a short circuit of the switches based on the divided voltage. When the divided voltage detected during an off period while the multiple switches are in off states is within a normal voltage range, the controller determines that no short circuit is occurred. When the divided voltage detected during the off period is out of the normal voltage range, the controller determines that a short circuit is occurred in at least one of the switches.