Trace Voltage Sensor for PCB Short Circuit Detection
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Solution Overview
Problem
Printed circuit boards in harsh environmental conditions, such as those exposed to humidity and salt, are prone to short circuits due to chemical reactions with trace materials, leading to potential system failures and catastrophic events, necessitating a method to remotely sense PCB failures and determine open or short circuit conditions.
Innovation Solution
A voltage sensor system is implemented on multi-layer printed circuit boards, featuring sensor circuits with sensing points and resistors near the edges of layers, coupled to a controller that compares voltage values to thresholds to detect abnormal circuit conditions like short or open circuits, allowing for timely warnings or shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If printed circuit boards are exposed to harsh environmental conditions (humidity, salt, heat), then the system can operate in field deployments, but copper bridges form between traces leading to short circuits
Solution Approach 1:
The sensor circuit is installed in advance on the PCB to continuously monitor trace voltage before failures occur. This preliminary monitoring enables early detection of copper bridge formation, allowing the system to take preventive action before short circuits develop, thus resolving the contradiction between environmental adaptability and circuit reliability
2Reliability
If traditional monitoring methods are used, then system simplicity is maintained, but early detection of PCB failures is not possible
Solution Approach 1:
The sensor circuit utilizes the PCB's existing trace network and power supply to create a self-contained monitoring system. The sensor leverages the PCB's own electrical infrastructure rather than requiring separate external monitoring equipment, enabling early failure detection while minimizing added system complexity
3Measurement precision
If sensor circuits are added to detect short circuits, then failure detection capability is improved, but the complexity of the circuit board increases
Solution Approach 1:
The sensor circuit is designed to share the PCB's existing power supply and ground traces, making the monitoring system multi-functional by utilizing already-present electrical infrastructure. This approach enables precise voltage sensing while avoiding the need for dedicated power and ground paths that would increase circuit board complexity
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
The system effectively detects potential short or open circuit failures, enabling proactive measures to prevent system malfunctions and failures by monitoring voltage changes across the circuit board layers, thereby ensuring operational reliability in harsh environments.
Implementation Method 1
the sensor circuit includes the trace network and a sensing point. The sensor circuit is coupled between a voltage supply and a ground. A controller is coupled to the sensing point. The controller is operable to determine a voltage of the sensing point
Implementation Method 2
sensor circuits with sensing points and resistors near the edges of layers
Data Source
AI summary
A voltage sensor system for determining an abnormal circuit condition in a multi-layer printed circuit board is disclosed. The printed circuit board has a plurality of layers. One of the layers includes a trace network and a sensor circuit. The sensor circuit includes the trace network and a sensing point. The sensor circuit is coupled between a voltage supply and a ground. A controller is coupled to the sensing point. The controller is operable to determine a voltage of the sensing point and compare the voltage to a threshold value to determine an abnormal circuit condition in the printed circuit board.