Transformer Intermediate Tap for Signal Diagnosis
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Solution Overview
Problem
Conventional methods for diagnosing signal status in measurement, drive, or control circuits require additional insulation power sources and complex circuitry, leading to increased manufacturing costs and complexity, especially when dealing with multiple contacts or electromagnetic valves.
Innovation Solution
A method and device that utilize a transformer with an intermediate tap to measure primary side current changes, allowing for signal status diagnosis without the need for insulation transformers, signal conversion, or demodulation circuits, using core materials with minimal temperature-dependent core loss to ensure accurate signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation power sources and complex circuitry are used for signal status diagnosis, then diagnosis capability is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The transformer is designed to perform multiple functions: it provides electrical insulation between primary and secondary circuits while simultaneously enabling signal status diagnosis through intermediate tap connection. The intermediate tap allows detection of primary side current changes that indicate secondary circuit conditions (wire breaks, short circuits, device status), eliminating the need for separate insulation power sources and complex diagnosis circuitry.
Solution Approach 2:
The invention merges the insulation function and the diagnosis function into a single transformer component. By connecting the intermediate tap to current measurement means, the transformer combines electrical isolation with diagnostic capability, integrating what were previously separate functions into one unified device.
2Reliability
If additional insulation components are added for diagnosis, then diagnosis accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The transformer serves dual purposes: maintaining electrical insulation and providing diagnosis functionality through its intermediate tap. This eliminates the need for additional insulation components, reducing part count and manufacturing cost while maintaining diagnosis accuracy through current change detection.
3Power
If core material with high core loss temperature dependence is used, then transformer performance is improved, but signal transmission accuracy deteriorates
Solution Approach 1:
The invention specifies using core material with minimal temperature-dependent core loss characteristics. This parameter selection ensures that the transformer maintains stable performance across temperature variations, allowing accurate detection of primary current changes that correspond to secondary circuit conditions without being obscured by temperature-induced variations in core loss.
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 high-accuracy signal status and circuit soundness diagnosis with a simpler construction, reducing manufacturing costs and eliminating the need for additional insulation components, while maintaining accurate transmission of measurement results and analog signals.
Implementation Method 1
a transformer with an intermediate tap to measure primary side current changes
Implementation Method 2
by measuring the change in primary side current caused by the consumption of the electric power supplied via the transformer
Data Source
Figure 1~3
Figure 4A~4B
Figure 5~7
AI summary
A device and method for diagnosing a signal status relating to measurement, drive, and control by a measuring means, a drive means, and a controlling means. The device and method enables prevention of an increase of manufacturing cost due to an increase of the number of parts or due to complication of the circuit scale and enables precise transmission of the measurement result and soundness diagnosis of a circuit by using a simple constitution. A means for generating an alternating current including a rectangular pulse is connected to the primary side of a transformer, and a driven body to be measured, driven, or controlled is connected directly to the secondary side or indirectly through a rectifier circuit to the secondary side. The power sent through the transformer is consumed by the movement of the driven body. Consequently, the variation of the primary current is measured, and the movement of the driven body and a signal status are diagnosed on the basis of the measurement result.