Switch Assembly Fault Detection via Motor Power and State Analysis
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Solution Overview
Problem
Existing methods for detecting faults in switch assemblies with electric motor-driven components are inefficient and require additional components, with power consumption influenced by switch states, making fault detection cumbersome and prone to interference.
Innovation Solution
A method that analyzes power consumption and switch state changes during the movement of a component from one position to another, using an analysis unit to trigger fault actions if specified power consumption and switch state changes are not met, ensuring low-effort fault detection without additional components and independent power consumption from switch states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components are added to detect faults in the switch assembly, then the reliability of fault detection is improved, but the device complexity increases
Solution Approach 1:
The system uses its own existing resources (power consumption measurements and switch state information) to perform fault detection, eliminating the need for additional dedicated fault detection components. The control unit analyzes data already available from normal operation to identify malfunctions.
Solution Approach 2:
The control unit performs multiple functions: it controls the drive, monitors power consumption, tracks switch states, and detects faults. This multi-functionality eliminates the need for separate dedicated fault detection hardware, reducing overall device complexity while maintaining detection reliability.
2Loss of information
If the switch state influences power consumption, then the power consumption reflects switch state information, but this creates interference in fault detection analysis
Solution Approach 1:
The system pre-establishes the expected relationship between switch states and power consumption patterns. By knowing in advance what power consumption changes should correspond to which switch state transitions, the system can distinguish normal variations from actual faults, filtering out interference before it affects detection accuracy.
Solution Approach 2:
The control unit continuously monitors both switch states and power consumption, comparing actual power consumption against expected values based on current switch states. This feedback mechanism allows the system to identify when power consumption deviates from expected patterns, indicating a fault rather than normal operation.
3Productivity
If brief peak currents or power surges are present during operation, then the power consumption varies dynamically, but this affects the accuracy of fault detection analysis
Solution Approach 1:
The system pre-establishes acceptable ranges and patterns for power consumption variations during normal operation, including expected peak currents and power surges. By having these reference patterns available beforehand, the system can distinguish between normal dynamic variations and actual fault conditions.
Solution Approach 2:
The control unit continuously compares actual power consumption measurements against expected patterns based on current operation state. When power consumption deviates from expected ranges, the system triggers fault detection, allowing it to filter out normal variations while detecting actual abnormalities.
Data Source
AI summary
A method for detecting faults in a switch assembly includes at least one switch for monitoring the position of a component that can be moved by means of a drive which has an electric motor includes shifting the movable component from a first position to a second position spatially separated from the first position, wherein the power consumption of the electric motor changes in a previously specified manner, and wherein the switch state of the switch during a proper functioning of the switch changes in a previously specified manner, analyzing the power consumption of the electric motor and the switch state of the switch in an analysis unit, and triggering a fault action if the power consumption of the electric motor has changed in the previously specified manner and the switch state of the switch has not changed in the previously specified manner.