Power-Line Data Coupling Between Circuit Modules Without Connectors
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Solution Overview
Problem
Existing data transmission methods between circuit modules in electrical devices, such as welding devices, photovoltaic inverters, and battery chargers, rely on costly and failure-prone connectors, which are problematic due to mechanical and thermal influences, and are not efficiently addressed by powerline communication due to interference and changing impedances.
Innovation Solution
Data transmission is achieved via the power supply lines using a modulation signal processed by the control device's digital interface, coupled into and decoupled from the power supply lines through a coupling circuit, utilizing inductive or capacitive methods, and demodulated without requiring carrier recovery, thus eliminating the need for separate connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate data cables with connectors are used to transmit data between circuit modules, then data transmission can be achieved, but connectors require space, are costly, and are prone to failure due to mechanical and thermal influences
Solution Approach 1:
The patent combines data transmission and power supply functions into a single cable system. The power supply cable that already connects circuit modules is used to carry both power and data signals, eliminating the need for separate data cables and connectors. This merging approach reduces the number of connectors, simplifies the device structure, and improves reliability by removing mechanical connection points that are susceptible to failure.
Solution Approach 2:
The power supply cable is given multi-functionality by enabling it to carry both power supply and data transmission functions. Instead of using dedicated data cables with specialized connectors, the existing power cable infrastructure is utilized for dual purposes, reducing component count and eliminating the reliability issues associated with additional connectors.
2Productivity
If connectors are used for data transmission between circuit modules, then data can be transmitted, but space requirements increase due to connector size
Solution Approach 1:
By merging data transmission with the existing power supply cable infrastructure, the patent eliminates the need for separate data connectors that would occupy additional space on circuit modules. The data signals are superimposed on the power cable, allowing data transmission without requiring any additional physical connection space.
3Device complexity
If powerline communication is used for data transmission between circuit modules, then connectors can be eliminated, but interference and changing impedances cause high error rates
Solution Approach 1:
The patent replaces the mechanical connector system with an electrical field-based communication system. Instead of using separate mechanical data connectors, the system uses electrical signals superimposed on the power supply lines to transmit data, thereby eliminating mechanical connection points while maintaining reliable transmission through proper signal processing.
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 method reduces mechanical failures, space requirements, and costs associated with connectors, while maintaining a low error rate and efficient data transmission, primarily suitable for short distances.
Implementation Method 1
coupled into the power supply lines via a coupling circuit provided in the circuit module... The modulation signal can be inductively coupled into or extracted from the power supply lines via an inductive coupling circuit, particularly a transformer
Implementation Method 2
The modulation signal can be capacitively coupled into or out of the power supply lines via a capacitive coupling circuit
Data Source
Figure 1~2
Figure 3A~3C
Figure 4
AI summary
The invention relates to a method and a device for transmitting data (D) between circuit modules (10) of an electrical device (1), which circuit modules (10) each contain a control device (11) with a memory (12) and a digital interface (13) and are connected to power supply lines (14).According to the invention, a coupling circuit (15) is provided in each circuit module (10), and the data (D) can be transmitted via the power supply lines (14), in that the control device (10) of each circuit module (10) is designed to transmit the data (D), to process the data (D), to form a modulation signal (M) from the processed data (D') using a clock signal (T), to forward the modulation signal (M) via the digital interface (13), to couple the modulation signal (M) into the power supply lines (14) via the coupling circuit (15), and to receive the modulation signal (M) from the power supply lines (14) via the coupling circuit (15), to transmit the modulation signal (M) via the digital interface (13) of the control device (11), to demodulate the modulation signal (M), and to extract the data (D) therefrom.