Power Converter Self-Testing Using DC Bus and Built-In Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical system testing processes are time-consuming and require additional equipment, often taking several days to complete and necessitating manual intervention.
Innovation Solution
A fully automated testing process for electrical systems that uses only the components of the electrical system employed during normal operation, including a power converter with DC and AC terminals, a DC bus with capacitors, a voltage and current sensor system, and a control unit to perform diagnostic tests without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual testing processes are used with additional testing equipment, then comprehensive diagnostic data can be obtained, but the testing time increases significantly and requires several days to complete
Solution Approach 1:
The existing electrical system components (power converter, DC bus, voltage sensors, current sensors, control unit) are made to serve dual purposes: normal operation and diagnostic testing. The control unit executes diagnostic routines using the same sensors and power electronics already present in the system, eliminating the need for dedicated testing equipment and reducing testing time while maintaining diagnostic capability
Solution Approach 2:
The electrical system performs self-diagnostics by using its own components to test itself. The control unit orchestrates diagnostic routines that utilize the system's inherent voltage sensors, current sensors, and power converter to generate and analyze test signals, allowing the system to monitor its own health without external testing equipment or manual intervention
2Reliability
If additional testing equipment and components are used to obtain necessary data, then comprehensive testing can be performed, but the device complexity and cost increase
Solution Approach 1:
The control unit is programmed to execute diagnostic routines that utilize existing system components for testing purposes. The same voltage sensors, current sensors, and power converter used during normal operation are repurposed for diagnostics, eliminating the need for additional testing equipment and reducing overall system complexity
Solution Approach 2:
The electrical system uses its own built-in components to perform comprehensive self-testing. The control unit coordinates diagnostic sequences that generate test signals through the power converter and measure responses using existing sensors, enabling complete system validation without external testing equipment
3Measurement precision
If manual testing processes are employed, then detailed diagnostic analysis can be performed, but the ease of operation decreases and requires skilled engineer intervention
Solution Approach 1:
The control unit automatically executes diagnostic routines without manual intervention. It generates test signals, collects sensor data, processes measurements, and generates fault diagnostics autonomously. The system self-monitors its components by coordinating diagnostic sequences and analyzing results, eliminating the need for skilled engineers to perform manual testing while maintaining diagnostic accuracy
Solution Approach 2:
The control unit continuously monitors system responses during diagnostic routines by collecting data from voltage sensors and current sensors. It compares measured values against expected ranges and automatically generates fault diagnostics based on deviations, providing real-time feedback on system health without manual analysis
Data Source
AI summary
A testing process for an electrical system is described. The electrical system includes a power converter and a direct current (DC) bus with two or more DC bus terminals and at least one DC bus capacitor. The testing process is a fully automated testing process where a sequence of different diagnostic tests are carried out on the electrical system, each diagnostic test testing one of the power converter and the DC bus to determine if it is responding as expected or operating within normal parameters.