Safety Load Switching Device Fault Detection

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Solution Overview

Problem

Existing load switching devices lack reliable detection of faulty electrical connections between current branches and potential sources, which can lead to unsafe continued operation of loads due to undetected faults in semiconductor switches or damaged insulation, causing incomplete disconnection.

Innovation Solution

A safety-oriented load switching device with test branches and measuring devices allows for individual testing of current branches for malfunctions and faulty connections, using current measuring devices like Hall sensors or magnetoresistive sensors, and a control system to evaluate and respond to potential faults, ensuring safe disconnection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If test branches with measuring devices are added to detect faulty connections, then detection reliability is improved, but device complexity increases

Engineering Contradiction:

Improvefault detection reliabilityVSAvoidcircuit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The device is divided into two independent current branches (first and second), each with its own switching means and test branch. This segmentation allows independent testing of each branch without affecting the other, enabling reliable fault detection while maintaining manageable circuit complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Test branches with measuring devices are integrated into the circuit design from the beginning, allowing preliminary detection of faulty connections before they cause safety issues. The test switches can be activated at predetermined times (e.g., during startup or maintenance periods) to proactively identify problems.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If individual testing of current branches is implemented, then safety is improved, but operational interruption increases

Engineering Contradiction:

ImprovesafetyVSAvoidoperational interruption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Testing of the current branches is performed periodically at predetermined times (e.g., during startup sequences, shutdown periods, or scheduled maintenance intervals) rather than continuously or requiring operational interruption. This allows safety checks to be conducted when the load is not in use, minimizing operational impact.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The testing function is designed to be dynamically integrated into the operational cycle, allowing tests to be performed during transition periods (startup/shutdown) when the load is temporarily inactive. The control system coordinates testing with operational requirements to minimize interruptions.

Inventive Principle:

Principle #15Dynamics

3Difficulty of detecting and measuring

If test switches are used to establish temporary connections for testing, then fault detection capability is improved, but energy discharge increases

Engineering Contradiction:

Improvefault detection capabilityVSAvoidenergy discharge

Core Design Contradiction:

Difficulty of detecting and measuringVSLoss of energy

Solution Approach 1:

Test switches serve as intermediaries that temporarily connect measuring points to supply connections during testing. These switches are controlled to close only for brief periods when testing is required, establishing temporary connections that enable fault detection without permanent circuit modifications or excessive energy discharge.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables reliable detection and response to faulty connections, preventing hazardous operation by ensuring complete disconnection of loads from supply, even in the presence of undetected faults or damaged insulation, thus ensuring safety and reliability.

Implementation Method 1

using current measuring devices like Hall sensors or magnetoresistive sensors

Methodology Applied

Scientific EffectHall effect: Hall Effect

Implementation Method 2

using current measuring devices like Hall sensors or magnetoresistive sensors

Methodology Applied

Scientific EffectMagnetoresistive effect: Magnetoresistance

Data Source

PatentUS9991074B2Safety-oriented load switching device and method for operating a safety-oriented load switching device

Publication Date: 2018.06.05 FESTO AG & CO KG

AI summary

A safety-oriented load switching device including a first current branch, which extends from a first supply connection to a first load connection and having a first switching means, and having a second current branch, which extends from a second supply connection to a second load connection and including a second switching means, wherein a first test branch is connected to a first measuring point located between the first switching means and the first load connection and is also connected to the second supply connection and includes a series connection of a first test switch and a first measuring device, wherein a second test branch is connected to a second measuring point between the second switching means and the second load connection and is connected to the first supply connection and includes a series connection of a second test switch and a second measuring device.