Programmable Discrete Output Module for Multi-Voltage Overcurrent Protection
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Solution Overview
Problem
Industrial control systems lack a versatile and efficient solution for detecting overcurrent events across various voltage levels and types, requiring multiple dedicated modules for different instruments, which increases complexity and cost.
Innovation Solution
A programmable discrete output module with a current sensing circuit, comparator, and microcontroller that generates a current sensing signal, compares it with an overcurrent reference, and controls a switching element to prevent current flow upon detecting an overcurrent event, using programmable parameters for different load types, and also includes isolators for galvanic isolation, enabling operation across 24V, 48V, 120V, and 240V AC/DC voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated output modules are used for different voltage levels and types, then overcurrent protection reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements a single output module capable of operating across multiple voltage levels (24V, 48V, 120V, and 240V AC/DC) by incorporating a programmable discrete output module with a switching element and isolators. The module uses a current sensing circuit and comparator to detect overcurrent events and control the switching element to prevent current flow, providing universal overcurrent protection functionality that replaces multiple dedicated modules for different voltage levels and types.
2Reliability
If multiple dedicated output modules are used for different voltage levels and types, then overcurrent protection reliability is improved, but cost increases
Solution Approach 1:
The patent implements a single output module capable of operating across multiple voltage levels (24V, 48V, 120V, and 240V AC/DC) by incorporating a programmable discrete output module with a switching element and isolators. The module uses a current sensing circuit and comparator to detect overcurrent events and control the switching element to prevent current flow, providing universal overcurrent protection functionality that replaces multiple dedicated modules for different voltage levels and types.
3Device complexity
If a single programmable module is used for multiple voltage levels, then device complexity and cost are reduced, but adaptability to different load types requires programmable parameters
Solution Approach 1:
The patent employs a microcontroller configured to control the switching behavior of the switching element based upon one or more programmable parameters corresponding to a load or load type interfaced with the programmable discrete output module. This dynamic configuration allows the single module to adapt to different load types and voltage levels through software programming rather than hardware changes, maintaining versatility while reducing physical complexity.
Solution Approach 2:
The patent employs a microcontroller configured to control the switching behavior of the switching element based upon one or more programmable parameters corresponding to a load or load type interfaced with the programmable discrete output module. This dynamic configuration allows the single module to adapt to different load types and voltage levels through software programming rather than hardware changes, maintaining versatility while reducing physical complexity.
4Reliability
If overcurrent protection is implemented with a switching element controlled by microcontroller, then protection effectiveness is improved, but response time may be compromised
Solution Approach 1:
The patent incorporates a current sensing circuit for generating a current sensing signal indicating a current value along an electrical path and a comparator communicatively coupled to the current sensing circuit, configured to compare the current value with an overcurrent reference. This preliminary detection and comparison mechanism is ready in advance, allowing the microcontroller to immediately control the switching element when an overcurrent event is detected, minimizing response time while maintaining effective protection.
Solution Approach 2:
The patent incorporates a current sensing circuit for generating a current sensing signal indicating a current value along an electrical path and a comparator communicatively coupled to the current sensing circuit, configured to compare the current value with an overcurrent reference. This preliminary detection and comparison mechanism is ready in advance, allowing the microcontroller to immediately control the switching element when an overcurrent event is detected, minimizing response time while maintaining effective protection.
Data Source
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Figure 3A~3B
AI summary
A programmable discrete output module (200) comprising: a current sensing circuit (208) for generating a current sensing signal indicating a current value; a comparator communicatively coupled to the current sensing circuit, the comparator configured to compare the current value with an overcurrent reference, the comparator configured to output a comparison signal indicating whether an overcurrent event has occurred; a switching element (202) configured to at least substantially prevent current flow within an electrical path when an overcurrent event has occurred; and a controller communicatively coupled to the comparator and the switching element, the controller configured to control the switching element based on whether an overcurrent event has occurred.