Insulation Transformer Tap Current Diagnosis for Actuator Faults
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Solution Overview
Problem
Conventional signal status diagnosing devices for external control means require additional circuits and components, increasing manufacturing costs and complexity, while existing methods for detecting wire breaks or short circuits are cumbersome and costly.
Innovation Solution
A signal status diagnosing device using an insulation transformer with an intermediate tap, a switch circuit operated by ON/OFF signals, and a current measuring means to diagnose the status of external control means without the need for separate power sources or signal conversion circuits, allowing for accurate diagnosis of wire breaks and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional circuits and components are added for signal status diagnosis, then diagnosis capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the power supply function and signal transmission function into a single integrated circuit. The insulation transformer serves both to provide isolated power to the external control means and to transmit the control signal simultaneously, eliminating the need for separate power supply circuitry and signal transmission circuitry.
Solution Approach 2:
The insulation transformer is designed with an intermediate tap that enables it to perform multiple functions: providing isolated power through the tap connection and transmitting control signals through the primary and secondary windings. This multi-functional component replaces what would traditionally require separate dedicated circuits for power and signal.
2Reliability
If separate power sources and signal conversion circuits are used, then power supply reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the power supply function and signal transmission function into a single integrated circuit. The insulation transformer serves both to provide isolated power to the external control means and to transmit the control signal simultaneously, eliminating the need for separate power supply circuitry and signal transmission circuitry.
Solution Approach 2:
The insulation transformer is designed with an intermediate tap that enables it to perform multiple functions: providing isolated power through the tap connection and transmitting control signals through the primary and secondary windings. This multi-functional component replaces what would traditionally require separate dedicated circuits for power and signal.
3Reliability
If conventional diagnosis methods are used, then wire break detection is achieved, but the number of parts increases
Solution Approach 1:
The patent combines the power supply function and signal transmission function into a single integrated circuit. The insulation transformer serves both to provide isolated power to the external control means and to transmit the control signal simultaneously, eliminating the need for separate power supply circuitry and signal transmission circuitry.
Solution Approach 2:
The circuit uses its own operational characteristics to perform self-diagnosis. By monitoring the current through the intermediate tap and comparing it with expected values, the system can detect wire breaks or short circuits without requiring external diagnostic equipment or additional sensing components.
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
The solution simplifies the circuit construction, reduces manufacturing costs, and enables high-accuracy diagnosis of external control means operation status without increasing the number of parts, allowing for real-time monitoring of wire breaks and short circuits.
Implementation Method 1
an insulation transformer (3) having an intermediate tap at a midpoint of its primary winding as said insulation means, to the secondary side of which being connected said external control means
Implementation Method 2
a current measuring means connected to the intermediate tap to measure a current which flows in the primary side of the insulation transformer corresponding to a current which flows in the secondary side
Data Source
Figure 1~3
Figure 4~5
Figure 6A~6B
AI summary
This aims to provide a signal status diagnosing device for an external control means, which is enabled even by a simple constitution to prevent the rise of a production cost due to the increase in a parts count or the complexity of a circuit constitution, and which can perform a signal status diagnosis of an actuator (the external control means) such as an electromagnetic valve, a lamp, a relay or a small-sized DC motor precisely. The signal status diagnosing device comprises a switch circuit connected with an intermediate tap disposed on the primary side of a transformer, for sending a driving electric power to the external control means disposed on the secondary side, in response to an ON/OFF signal of the external control means, and a means connected with the switch circuit and driven by the external control means, for measuring the primary side electric current to flow in a manner to correspond to the electric current to flow to the transformer secondary side. The signal status diagnosing device diagnoses the signal status of the external control means in accordance with the measurement result of the current measuring means.