Vehicle PCB Leakage Current Detection for Safety-Critical Circuits

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing circuit devices in vehicles fail to effectively detect and mitigate unwanted current paths, particularly in safety-critical systems like braking and steering systems, leading to potential system failures and safety risks.

Innovation Solution

A circuit device with a detection electrode and arrangement that monitors conductor tracks for leakage currents, providing detection signals to correct, switch off, or warn against unsafe conditions, using a detection electrode integrated into the printed circuit board or connector.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional circuit devices are used without detection electrodes, then the device complexity is low, but the reliability is insufficient due to undetected leakage currents

Engineering Contradiction:

Improvedetection of leakage currentVSAvoidcircuit device structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The detection electrode is integrated directly into the printed circuit board structure, merging the detection function with the existing PCB layout. This eliminates the need for separate detection components and reduces overall device complexity while enabling leakage current detection for improved reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The printed circuit board serves multiple functions: it provides mechanical support, electrical connections through conductor tracks, and leakage current detection through the integrated detection electrode. This multi-functionality reduces the need for additional dedicated detection components, maintaining simplicity while improving reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If complex geometries and additional insulation are used to prevent leakage currents, then the reliability improves, but the manufacturing precision and production complexity increase

Engineering Contradiction:

Improveprotection against leakage currentVSAvoidinsulation and geometry requirements

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical/physical protection methods (complex geometries, additional insulation layers, sealed connectors) with an electrical detection system. The detection electrode monitors leakage currents electrically, eliminating the need for complex physical barriers and reducing manufacturing precision requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection electrode is formed using the same PCB manufacturing processes as the conductor tracks, allowing the system to detect its own leakage issues without requiring external inspection or additional protective structures. The PCB structure serves itself for both signal transmission and leakage detection

Inventive Principle:

Principle #25Self-service

3Reliability

If sealed connectors and lacquered connection points are used to prevent leakage, then the reliability improves, but the device complexity and production complexity increase

Engineering Contradiction:

Improveinsulation effectivenessVSAvoidproduction complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical sealing methods (sealed connectors, lacquered surfaces) with an electrical monitoring approach. The detection electrode continuously monitors for leakage currents, providing reliability without requiring complex sealing processes or additional manufacturing steps

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of changing the physical state or structure of connectors and connection points through sealing and lacquering, the patent changes the monitoring approach by adding detection capability. This allows the system to maintain simple, easy-to-manufacture connectors while achieving reliability through electrical parameter monitoring

Inventive Principle:

Principle #35Parameter changes

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 mitigation of leakage currents, ensuring safe operation of safety-critical systems by actively detecting and correcting unwanted current paths without complex geometries or additional insulation, facilitating compliance with safety standards and reducing production complexity.

Implementation Method 1

a detection electrode for detecting a leakage current affecting at least one of the conductor tracks; and a detection arrangement configured to use a signal applied to the detection electrode in order to provide a detection signal representing the leakage current

Methodology Applied

Scientific EffectElectrical signal detection: Conduction (electrical)

Data Source

PatentUS12504457B2Circuit device for a vehicle, and method for operating a circuit device

Publication Date: 2025.12.23 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

AI summary

A circuit device for a vehicle, including: a printed circuit board having an operating circuit for operating a unit, a first conductor track for connecting the operating circuit to the unit, and a second conductor track for connecting the operating circuit to the unit; a detection electrode for detecting a leakage current affecting at least one of the conductor tracks; and a detection arrangement to use a signal applied to the detection electrode to provide a detection signal representing the leakage current. Also described are a related method.