Overload protection method
This invention relates to fault detection in electrical circuits. The invention provides a switch for a fault tolerant digital output module comprising: an output transistor pair for enabling and disabling an alternating output current; and a current limiter for clamping the output current to a predetermined maximum value.
1. A switch for a fault tolerant digital output module comprising:
an output transistor pair for enabling and disabling an alternating output current;
a current limiter circuit clamping the output current to a predetermined maximum value and maintaining current flow through the output transistor pair;
a voltage monitor for monitoring the voltage across the output transistor pair and which sets an overvoltage signal in the event that the monitored voltage exceeds a predetermined maximum voltage and which is arranged in operation to sample the overvoltage signal at overvoltage sampling intervals and in the event that the output transistor is enabling the output alternating current and the overvoltage signal is set for more than a predetermined number of voltage samples an overload condition is detected.
2. A switch according to claim 1 , in which:
the current limiter circuit comprises a current sense resistor connected in series with the output transistor pair and a pair of current limiting transistors; and
the voltage sampling interval is substantially equal to 60 μs, the predetermined maximum voltage value is substantially between 10V and 35V and the predetermined number of voltage samples is equal to 1, 2, 3 or 4.
3. A switch according to claim 1 , further comprising a current monitor for monitoring the current through the output transistor pair and which is arranged in operation to sample the current at current sampling intervals and in the event that the current exceeds a predetermined absolute maximum current value for more than a predetermined number of current samples an overload condition is detected.
4. A switch according to claim 3 , in which the current sampling interval is substantially equal to 240 μs and the predetermined number of current samples is in the range 1-4.
5. A switch according to claim 3 , further comprising an average current monitor for monitoring the average current through the output transistor pair and which is arranged in operation to sample the average current at average current sampling intervals and in the event that the average current exceeds an average current predetermined threshold for more than a predetermined number of AC cycles an overload condition is detected.
6. A switch according to claim 5 , in which the average current sampling interval is substantially equal to 300 ms and the predetermined number of AC cycles is 3.
7. A switch according to claim 5 wherein a first length of time calculated by the overvoltage sampling interval multiplied by the predetermined number of voltage samples to detect an overload condition is less than a second length of time calculated by the current sampling interval multiplied by the predetermined number of current samples to detect an overload condition.
8. A switch according to claim 7 wherein a third length of time calculated by the period of one AC cycle multiplied by the predetermined number of AC cycles is greater than the second length of time.
9. A switch for a fault tolerant digital output module comprising:
an output transistor pair for enabling and disabling an output current;
a current limiter circuit clamping the output current to a predetermined maximum value and maintaining current flow through the output transistor pair;
a voltage monitor circuit for monitoring the voltage across the output transistor pair wherein an overvoltage signal is set if the monitored voltage exceeds a predetermined maximum voltage;
a current monitor circuit for monitoring the current through the output transistor pair; and
a processor sampling the overvoltage signal at overvoltage sampling intervals and sampling the current at current sampling intervals, wherein:
the processor sets an overload condition signal if the overvoltage signal is set for more than a predetermined number of overvoltage sampling intervals,
the processor sets the overload condition signal if the current exceeds a predetermined maximum current value for more than a predetermined number of current sampling intervals,
the processor determines an average current value, and
the processor sets the overload condition signal if the average current value exceeds a predetermined average current threshold for more than a predetermined length of time.