Voltage Regulator Diagnostic System Using Microcontroller ADCs
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Solution Overview
Problem
Current diagnostic systems for voltage regulators lack effective methods to determine if they are operating within desired voltage ranges, leading to potential failures and inefficiencies.
Innovation Solution
A diagnostic system utilizing a microcontroller with analog-to-digital converters and multiplexers, coupled with a voltage step-down circuit, to monitor voltage outputs from both the voltage regulator and the step-down circuit, setting flags for fault conditions and controlling a contactor based on threshold values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single voltage monitoring method is used, then the device complexity is reduced, but the reliability of voltage regulator diagnostics is insufficient
Solution Approach 1:
The patent applies local quality by implementing different diagnostic methods for different voltage monitoring needs. The system uses a first diagnostic function that directly monitors voltage regulator output and a second diagnostic function that monitors voltage step-down circuit output, with each function having its own analog-to-digital converter and multiplexer configuration. This localized differentiation of diagnostic approaches enhances overall reliability without requiring complete system redesign.
Solution Approach 2:
The diagnostic system is segmented into multiple independent monitoring paths. Each path includes separate analog multiplexers, analog-to-digital converters, and diagnostic functions that can operate independently. This segmentation allows the system to maintain high reliability through redundant monitoring while managing complexity by organizing diagnostics into modular, independent units.
2Measurement precision
If multiple diagnostic functions are implemented, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The microcontroller is designed with universal diagnostic capabilities that can perform multiple functions through software configuration. The same hardware infrastructure (microcontroller, multiplexers, analog-to-digital converters) supports both the first diagnostic function for voltage regulator monitoring and the second diagnostic function for voltage step-down circuit monitoring, enabling multi-functionality without proportionally increasing hardware complexity.
Solution Approach 2:
Analog multiplexers serve as intermediaries that allow a single analog-to-digital converter to service multiple voltage monitoring points. The multiplexers selectively connect different voltage sources to the converter based on which diagnostic function is active, enabling precise measurement of multiple voltages while reducing the number of required converters and associated complexity.
Data Source
AI summary
A diagnostic system for a voltage regulator is provided. The diagnostic system includes a microcontroller having first and second analog-to-digital converters and first and second output ports. The first analog-to-digital converter outputs a first voltage value corresponding to the first voltage from the voltage regulator. The microcontroller executes a first diagnostic function to set a first voltage regulator diagnostic flag equal to a fault value indicating a voltage out of range condition, if the first voltage value is greater than a first threshold voltage value or the first voltage value is less than a second threshold voltage value. The microcontroller executes a second diagnostic function to stop generating first and second control signals to de-energize a contactor coil to open a contact of a contactor if the first voltage regulator diagnostic flag is equal to the fault value.