Wetting current diagnostics

• US 10,641,827 B2
• Filed: 08/14/2018
• Issued: 05/05/2020
• Est. Priority Date: 02/18/2015
• Status: Active Grant

• Current Assignee: NXP USA, Inc. (NXP Semiconductors NV)
• Original Assignee: NXP USA, Inc. (NXP Semiconductors NV)
• Inventors: Edwards, William E., Gray, Randall C., Andresen, Anthony F.
• Primary Examiner(s): McAndrew, Christopher P
• Application Number:
  US16/103,349
• Publication Number:
  US 20180356466A1
• Time in Patent Office: 630 Days
• Field of Search: 324418
• CPC Class Codes: G01R 19/16571 comparing AC or DC current with one threshold, e.g. load current, over-current, surge current or fault current G01R19/16514, G01R19/16519, G01R19/16528, G01R19/16533, G01R19/1659 take precedence; measuring currents by using elements sensitive to the magnetic field generated G01R15/14; measuring earth resistance G01R27/18; testing for leakage or short circuits in electrical apparatus G01R31/52
• CPC Class Codes: G01R 31/3277 of low voltage devices, e.g. domestic or industrial devices, such as motor protections, relays, rotation switches
• CPC Class Codes: G01R 31/3278 of relays, solenoids or reed switches measuring contact resistance G01R27/205; high voltage magnetic switches G01R31/3271, G01R31/333; testing electric windings G01R31/72; monitoring of fail safe circuits H01H47/002
• CPC Class Codes: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H03K 17/18 Modifications for indicating state of switch
• CPC Class Codes: H03K 2217/0027 Measuring means of, e.g. currents through or voltages across the switch

Abstract

A circuit for diagnostic testing includes a current source coupled to a power source and configured to provide wetting current along a path to a load control switch, a current sensor connected in series with the current source along the path, the current sensor being configured to generate a current sensor signal indicative of a current level along the path, a voltage measurement unit having an input terminal coupled to a node along the path through which the wetting current flows to reach the load control switch, the voltage measurement unit being configured to detect a state of the load control switch based on a voltage at the node, and a controller coupled to the current sensor and the voltage measurement unit, the controller being configured to determine a wetting current diagnostic condition in accordance with the current level and the detected state.

Claims

1. A method of providing wetting current diagnostics for a load control switch, the method comprising:

detecting a state of the load control switch;

measuring a current level of a wetting current;

when the detected state is an open state, determining, based on the measured current level, whether the state of the load control switch is detected correctly by comparing the measured current level to first and second open switch current thresholds;

when the detected state is a closed state, comparing the measured current level to a closed switch current threshold; and

providing at least one of;

(i) a voltage offset fault alert if the measured current level falls between the first and second open switch current thresholds and if a measured voltage is above a voltage reference, the measured voltage measured at a node through which the wetting current passes to the load control switch, and (ii) a leakage fault alert if the measured current level falls between the first and second open switch current thresholds and the measured voltage is below the voltage reference.

2. The method of claim 1, further comprising providing a wetting current fault notification when the measured current level falls outside of a range of current levels relative to the closed switch current threshold.

3. The method of claim 1, further comprising:

selecting a test input voltage; and

testing operation of a voltage measurement unit by comparing the test input voltage with a voltage reference.

4. A method of providing wetting current diagnostics for a load control switch, the method comprising:

providing, by a current source coupled to a power source, a wetting current along a path to the load control switch;

generating, by a current sensor connected in series with the current source along the path, a current sensor signal indicative of a current level along the path;

detecting, by a voltage measurement unit having an input terminal coupled to a node along the path through which the wetting current flows to reach the load control switch, a state of the load control switch based on a voltage at the node;

determining, by a controller coupled to the current sensor and the voltage measurement unit, a wetting current diagnostic condition in accordance with the current level and the detected state of the load control switch;

if the current level is above an open threshold current level with the load control switch in an open position, deactivating, by the controller, the current source to determine a voltage level at the node with the current source deactivated;

generating, by the controller, a voltage offset fault alert if the voltage level remains above a threshold voltage level upon deactivation; and

generating, by the controller, a leakage fault alert if the voltage level falls below the threshold voltage level upon deactivation.

5. The method of claim 4, further comprising:

receiving, by a current measurement unit coupled to the current sensor and to the controller, the current sensor signal;

generating, by the current measurement unit, an output signal indicative of a comparison of the current level with a threshold current level; and

determining, by the controller, the wetting current diagnostic condition based on the output signal.

6. The method of claim 5, further comprising:

correlating, by the controller, operation of the voltage measurement unit and the current measurement unit.

7. The method of claim 5, further comprising:

implementing, by the controller, first and second diagnostic routines when the voltage measurement unit detects that the state of the load control switch is open and closed, respectively,

wherein the first diagnostic routine is configured to determine whether the voltage measurement unit is operating correctly, and

wherein the second diagnostic routine is configured to compare the current level with the threshold current level.

8. The method of claim 4, further comprising:

providing a low current alert, by the controller, if the current level falls below a current range; and

providing a high current alert, by the controller, if the current level is above the range.

9. The method of claim 4, further comprising:

providing a switch detection fault alert, by the controller, while receiving an indication of an open state of the load control switch, if the current level is within a range of current levels expected to be reached with the load control switch closed.

10. The method of claim 4, further comprising:

selecting, by the controller, a state of a switch that couples the input terminal of the voltage measurement unit to either a voltage reference source or the node.

11. A method of providing wetting current diagnostics for a load control switch, the method comprising:

providing, by a current source coupled to a power source, a wetting current along a path to the load control switch;

generating, by a current sensor connected in series with the current source along the path, a current sensor signal indicative of a current level along the path, the current sensor comprising a diode disposed in the path and a current mirror connected across the diode;

receiving, by a current measurement unit coupled to the current sensor, the current sensor signal;

comparing, by the current measurement unit, the current level with an open switch threshold and a closed switch threshold, the current measurement unit comprising a voltage comparator and a resistive load driven by the current mirror;

detecting, by a voltage measurement unit having an input terminal coupled to a node along the path through which the wetting current flows to reach the load control switch, a state of the load control switch based on a voltage at the node;

determining, by a controller connected to the current measurement unit and the voltage measurement unit, a wetting current diagnostic condition in accordance with the comparisons and the detected state; and

comparing, by the voltage comparator, a voltage across the resistive load with a reference voltage.

12. The method of claim 11, wherein:

implementing, by the controller, first and second diagnostic routines when the voltage measurement unit detects that the state of the load control switch is open and closed, respectively,

wherein the first diagnostic routine is configured to detect whether the state of the load control switch is detected correctly based on the comparisons of the current level with the open and closed switch thresholds, and

wherein the second diagnostic routine is configured to compare the current level with the closed switch threshold.

13. The method of claim 11, wherein the current sensor comprises a common base amplifier circuit.

14. The method of claim 11, wherein the current measurement unit comprises an active load.

15. A method of providing wetting current diagnostics for a load control switch, the method comprising:

providing, by a current source coupled to a power source, a wetting current along a path to the load control switch;

generating, by a current sensor connected in series with the current source along the path, a current sensor signal indicative of a current level along the path;

receiving, by a current measurement unit coupled to the current sensor, the current sensor signal;

comparing, by the current measurement unit, the current level with an open switch threshold and a closed switch threshold;

detecting, by a voltage measurement unit having an input terminal coupled to a node along the path through which the wetting current flows to reach the load control switch, a state of the load control switch based on a voltage at the node; and

determining, by a controller connected to the current measurement unit and the voltage measurement unit, a wetting current diagnostic condition in accordance with the comparisons and the detected state;

wherein the current sensor comprises a resistor disposed in the path and a transistor coupled to the resistor such that a voltage drop across the resistor controls an extent to which the transistor is activated.

16. The method of claim 15, wherein:

implementing, by the controller, first and second diagnostic routines when the voltage measurement unit detects that the state of the load control switch is open and closed, respectively,

wherein the first diagnostic routine is configured to detect whether the state of the load control switch is detected correctly based on the comparisons of the current level with the open and closed switch thresholds, and

wherein the second diagnostic routine is configured to compare the current level with the closed switch threshold.

17. The method of claim 15, wherein the current sensor comprises a common base amplifier circuit.

18. The method of claim 15, wherein the current measurement unit comprises an active load.