Abstract:
A solid state switch that employs a controller driven input and MOSFET power switching devices is disclosed. The controller can test for a short-circuit on the load side of the MOSFET power switching devices before putting the switch in a sustained conductive state.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 60/825,286, filed Sep. 12, 2006, the entirety of which is incorporated herein by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to the field of solid state switching devices. In particular, to a solid-state switch with short circuit protection. 
       BACKGROUND 
       [0003]    A switching circuit, such as a relay or a triac, is typically employed to switch high voltage/power circuits with a lower voltage/power control signal. The control signal is generated by a secondary (control) device. Current switching applications (for example a Class 2 application switching a voltage less than 30V) typically use switching technologies including relays or triac devices. Other applications may include opto-isolated Field Effect Transistors (FET); typically, these circuits are limited to maximum load currents of a few milliamps (mA). 
         [0004]      FIG. 1  is a schematic representation of an exemplary relay switch  100  that works through energizing (V Con ) a coil  110  that acts as a magnet to pull down a gate  120  that connects a high voltage (V High ) to the power circuit and enables a current flow. Latching relays (not illustrated) can have one or two coils. An impulse closes the circuit and a feedback loop keeps the gate closed. A reverse pulse opens the circuit or a second coil is energized to open the circuit. 
         [0005]    The following limitations with relays are based on the analysis of a Class 2 application operating below 30V alternating current (AC). These limitations may also apply to circuits operating outside the 30V AC range:
       When used in an application such as thermostat control, the operating voltage is typically 24V and the dissipation is 140 mW (for a non-latching relay). The operating range of a thermostat is between 18 and 30V, and at 30V the power dissipation increases to 220 mW. The thermostat control can typically run three devices (i.e. three loads each having an associated relay) resulting in a total power dissipation of approximately 600 mW. This adds significant heat to a temperature sensitive thermostatic control.   A further limitation of relays is arcing. Arcing occurs when the load current momentarily bridges the air gap as the relay gate opens. This causes electromagnetic (EM) noise and radio frequency (RF) interference that can adversely affect the operation of the thermostat, or other devices, particularly RF devices. In addition, when opening the relay gate, the sudden cutting off of control current in the relay coil also causes a momentary voltage spike in the control circuit potentially causing failure in the electrical components of the device.   Secondary parts such as voltage suppressors can be used to reduce the voltage arcing, although these add to cost and space requirements on circuit boards.   A relay can also degrade over time and may be ineffective when switched from a high power to a low power application. The contact surfaces wear out which degrades their ability to form a proper contact in a low power application.   The relay is also limited in the number of times it can switch in a lifetime, typically from 100K to 1M operations.   Switching of the relay is limited to a few cycles per minute.   In the event of a controller failure, the coil may be latched and continue running the appliance indefinitely (applies to latching relays only).   There is no inherent short circuit protection on a relay device.   Relays (regular and especially the latching type) are typically more expensive and occupy more volume than corresponding solid state devices.       
 
         [0015]    The following limitations with triacs are based on the analysis of a Class 2 application operating below 30V AC. These limitations may also apply to circuits operating outside the 30V AC range:
       Triacs can only operate in an AC application (i.e. with an AC powered load).   Triacs require a switching current and have a typical voltage drop of 1-2V. They are not suitable for millivolt (mV) applications.   A limitation to triacs also relates to brownout conditions. In a brownout condition, the controlled voltage can drop to 18V. If a triac operates with a 2V drop, an overall 16V signal may be too low for proper operation.   Since the control signal is 5 to 20 mA, the heat dissipation can be significant.   Triacs usually require secondary circuitry to isolate the source and switching voltage. This is commonly done with opto-couplers which add to overall costs of the device.   By way of an example, a Triac switching 300 mA of current per circuit with 3 circuits active at once having a 2V drop will dissipate 1.8 W of power, which will add significant thermal offset to a thermostat application where accurate temperature readings are desired. In comparison, an exemplary MOSFET circuit in a similar application will dissipate 0.054 W of power.   Triacs may have leakage current through the device. In a low power application, the small (leakage) current may be interpreted as a false signal.       
 
         [0023]    What is needed is a switching mechanism for switching high voltage/power circuits with a lower voltage/power control signal that mitigates some or all of the disadvantages described above. 
       SUMMARY OF INVENTION 
       [0024]    A solid state switch that employs a controller driven input, and MOSFET power switching devices is disclosed. The controller can test for a short-circuit on the load side of the MOSFET power switching devices before putting the switch in a sustained conductive state. 
         [0025]    In one aspect of the present invention there is provided, a method of operating a microprocessor controlled solid-state switch having a metal-oxide semiconductor field-effect transistor (MOSFET) based output stage for switching a load, the method comprising the steps of: receiving a command to put the solid-state switch in a conductive state; checking a wait timer for a zero duration; repeating the step of checking, when the duration is non-zero; generating an input signal pulse from the microprocessor to put the output stage in a conductive state, when the duration is zero; taking a sample voltage at the output stage; responsive to the sample voltage, determining that the switch is in one of a short-circuit condition and a non-short-circuit condition; resetting the wait timer to a pre-determined non-zero value and repeating the step of checking, when the switch is in a short-circuit condition; and generating an input signal from the microprocessor to put the output stage in a sustained conductive state, when the switch is in a non-short-circuit condition. 
         [0026]    In another aspect of the present invention there is provided, a solid-state switch, for switching a load, comprising: a booster circuit for receiving a substantially square-wave input signal, electrically decoupling the signal, and generating a control signal that is an amplified version of an envelope of the input signal; a filter circuit for receiving the control signal and reshaping the signal into a output stage driving signal having smaller rise and fall times; an output stage having one or more metal-oxide semiconductor field-effect transistors (MOSFET), for receiving the output stage driving signal and responsive to the output stage driving signal putting the MOSFET in one of a conductive and a non-conductive state; a microprocessor for: receiving a command to put the solid-state switch in a conductive state; checking a wait timer for a zero duration; repeating the step of checking, when the duration is non-zero; generating an input signal pulse from the microprocessor to put the output stage in a conductive state, when the duration is zero; taking a sample voltage at the output stage; responsive to the sample voltage, determining that the switch is in one of a short-circuit condition and a non-short-circuit condition; resetting the wait timer to a pre-determined non-zero value and repeating the step of checking, when the switch is in a short-circuit condition; and generating an input signal from the microprocessor to put the output stage in a sustained conductive state, when the switch is in a non-short-circuit condition. 
         [0027]    Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art or science to which it pertains upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0028]    The present invention will be described in conjunction with drawings in which: 
           [0029]      FIG. 1  is a schematic representation of an exemplary relay switch. 
           [0030]      FIG. 2  is a schematic representation of an exemplary solid-state switch in situ in an exemplary thermostat control. 
           [0031]      FIG. 3  is a schematic representation of an exemplary boost circuit. 
           [0032]      FIG. 4  is a schematic representation of an exemplary signal V Control . 
           [0033]      FIG. 5  is a schematic representation of an exemplary signal V Threshold . 
           [0034]      FIG. 6  is a schematic representation of an exemplary filter circuit. 
           [0035]      FIG. 7  is a schematic representation of an exemplary signal V MOS . 
           [0036]      FIGS. 8A and 8B  are schematic representations of exemplary output stages. 
           [0037]      FIG. 9  is a schematic representation of an exemplary signal V Out  illustrating a normal and a short circuit condition at zero crossing. 
           [0038]      FIG. 10  is a schematic representation of a DC signal V Out  illustrating a normal and a short circuit condition. 
           [0039]      FIG. 11  is a flowchart representing steps in an exemplary control algorithm for the solid state switch. 
           [0040]      FIG. 12  is a schematic representation of a configuration for detecting short circuits at the output stage  240 . 
       
    
    
     DETAILED DESCRIPTION  
       [0041]      FIG. 2  is a schematic representation of an exemplary solid-state switch  200  in situ in an exemplary thermostat control  250 . The solid-state switch  200  (herein after the switch) comprises a controller driven input  210 , a boost circuit  220 , a filter circuit (a.k.a. a latching circuit)  230 , and an output stage  240 . The controller driven input  210  can, for example, receive a signal from a microprocessor  270  (e.g. the Microchip Technology Inc. PIC 18F6527) or other similar well known programmable device (e.g. microcontrollers, Programmable Gate Arrays (PGA), Programmable Logic Arrays (PLA), Application-Specific Integrated Circuits (ASIC)) capable of providing a control function signal. The exemplary thermostat control  250  comprises a power supply  260 , an alternating current (AC) to direct current (DC) converter  265 , a signal conditioning unit  262 , a microprocessor  270  having an analog to digital converter  275 , a communication unit  280 , a display unit  285 , buttons  290  for user input, sensors  295  and one or more solid state switches  200 . 
         [0042]      FIG. 3  is a schematic representation of an exemplary boost circuit  220 . The boost circuit  220  is provided with a low power high frequency signal (V 1 ) at the input  210  by the microprocessor  270 . The signal V 1  is boosted through the boosting circuitry through the combination of a resistive network (R 1  &amp; R 2 ) and an NPN transistor (N 1 ). Voltage V 2  is substantially higher than the maximum voltage of the signal V 1 . Voltage V 2  can be derived from the AC-DC converter  265  (connection not illustrated). Further, the circuit uses two capacitors (C 1  &amp; C 2 ) to provide signal isolation. The isolated signal is passed through a peak-detector which uses two diodes (D 1  &amp; D 2 ) and a capacitor (C 3 ). The output of the boost circuit is referred to as V Control . The smaller the capacitance of C 1  &amp; C 2 , the greater the isolation. The increased isolation comes at the expense of increased rise and fall times (i.e. increased wave-like attenuation of the signal) of V Control .  FIG. 4  is a schematic representation of an exemplary signal V Control  and the signal V 1  from which it was derived. In  FIG. 4  and in all other figures in this document representing voltage signals the vertical dimension represents voltage increasing from bottom to top and the horizontal dimension represents time increasing from left to right, unless otherwise specified. The output signal V Control  represented in  FIG. 4  is the result of applying a square wave input signal V 1  to the boost circuit  220 . The increased rise and fall times can be seen in the sloped vertical signal components and the rounded shoulders of the signal V Control . 
         [0043]    The output signal V Control  is an amplified version of the envelope of signal V 1 . The waveform of signal (V Control ) is unfavorable for application to MOSFET devices due to the highly resistive nature of MOSFET devices when turned on at V Threshold .  FIG. 5  is a schematic representation of an exemplary signal V Control . In  FIG. 5  the vertical axis represents the internal resistance of a MOSFET device, increasing from bottom to top, and the horizontal axis represents time increasing from left to right. The label V Threshold  on the horizontal axis represents the point in time that corresponds to the gate voltage applied to the MOSFET device achieving V Threshold . In an illustrative example represented in  FIG. 5 , the MOSFET device is in series with a 24Ω load. At 24V and 1 A of load current, the power loss through the MOSFET during switching would be substantial when switching is prolonged (i.e. the time delay to achieving V Threshold  is significant), which would significantly impact the operation of a temperature sensitive device such as, for example, a thermostat control. Further, the power dissipation through the MOSFET could lead to its destruction under short circuit conditions. 
         [0044]      FIG. 6  is a schematic representation of an exemplary filter circuit  230 . To address the above described problem, the signal V Control  is fed through the filtering circuit  230  comprised of a resistive network (R 3  to R 6 ) and transistor network (N 2  &amp; N 3 ) that create an output signal V MOS  for input to the output stage.  FIG. 7  is a schematic representation of an exemplary signal V MOS  and the signal V Control  from which it was derived. The waveform (V MOS ) has a substantially square waveform that significantly limits the time in which the MOSFET transistors operate in a highly resistive mode during on/off transitions. By improving the rise and fall times compared to V Control  the signal V MOS  minimizes the delay in achieving V Threshold  at the gate of the MOSFET devices. 
         [0045]      FIG. 8A  is a schematic representation of an exemplary output stage  240 . V MOS  is fed into the output stage  240 . The output stage  240  comprises a dual N-channel MOSFET circuit (Q 1  and Q 2 ) that controls the output voltage V Out . The signal V MOS  is applied to the gates of the MOSFET devices Q 1 , Q 2 . The load to be controlled (i.e. switched ON and OFF) and a high voltage (V High ) source (not illustrated) can be connected in series with the drains of the MOSFET devices Q 1 , Q 2 . 
         [0046]      FIG. 8B  is a schematic representation of an alternative exemplary output stage  240  comprising a dual P-channel MOSFET circuit (Q 1  and Q 2 ). The embodiment of  FIG. 8B  operates in substantially the same way as the embodiment of  FIG. 8A  except that signal V MOS  is applied to the sources of the MOSFET devices Q 1 , Q 2 . 
         [0047]    In a further alternative embodiment (not illustrated) for DC switching only, the output stage  240  comprises a single MOSFET device (Q 1 ). V High  and the load are connected respectively to the drain and the source of Q 1 . V MOS  is applied between the gate and the source of Q 1 . 
         [0048]    Prior to the microprocessor  270  signaling the output stage  240  into a sustained ON (i.e. conductive) state, it can pulse the input  210  of the switch  200  and sample the voltage at the output stage  240  to detect short circuits in either AC or DC applications.  FIG. 12  is a schematic representation of a configuration for detecting short circuits at the output stage  240 . The signal conditioning unit  262  is connected between the source of V High  (e.g. power supply  260 ) and the output stage  240  in order to sense V High . The microprocessor  270  in conjunction with the signal conditioning unit  262  is able to analyze the sensed voltage V High . 
         [0049]      FIG. 9  is a schematic representation of an exemplary sensed (i.e. sampled) signal V High  illustrating (in the expanded views) both a normal (i.e. non-short-circuit) (V Normal ) and a short circuit (V short-circuit ) condition at zero crossing. A typical AC signal has a zero crossing where the slope of the change in voltage is at a maximum. At the zero crossing, the microprocessor  270  pulses the input signal V 1  to turn the output of the switch  200  on and tests the voltage at the crossing. If the slope (i.e. the rate of change of the voltage) is below a desired threshold (V Threshold ), the microprocessor  270  interprets that the load-side of the output stage  240  is in a short circuit state (V short-circuit ) and the microprocessor stops (i.e. de-asserts) the signal V 1 , allowing the output stage  240  to go into an OFF (i.e. open) state preventing damage to the output stage  240  and connected devices (e.g. the load). 
         [0050]      FIG. 11  is a flowchart representing steps in an exemplary control algorithm (i.e. method)  1100  for the solid-state switch  200 . The method  1100  allows the microprocessor  270  to detect an unexpected slope and reset the output stage  240  to an OFF state. The microprocessor  270  receives an ON command  1110  which, in the example of a thermostat application, may be a signal to turn on the fan, heat, AC, or other external circuits. A “wait” timer is checked  1120 . When the timer duration is non-zero, it indicates that a short circuit fault has been previously detected and processing returns to step  1120 . The timer duration is zero (“0”)  1130  when no short circuit fault has been previously detected or when a previously non-zero timer duration has expired; processing continues at step  1140 . The microprocessor  270  detects a zero voltage crossing  1140 , generates a short duration series of output driving pulses  1150 , takes a sample of the AC voltage and computes the slope  1160 . If the signal slope (e.g. V Normal ) is greater than the threshold slope (V Threshold )  1170  indicating a non-short-circuit (i.e. normal) condition, then the microprocessor activates the desired output  1180 . If the signal slope (e.g. V short-circuit ) is less than the threshold slope (V Threshold ) indicating that a short circuit is detected, then the microprocessor resets the timer duration to a predetermined non-zero value  1190 . 
         [0051]    Referring again to  FIG. 12 , in an alternative embodiment of the apparatus and method for the solid-state switch  200 , in order to detect a short circuit on the output stage  240  in a DC application (i.e. a DC load), an inductor  300  is placed in series with the load  310  between the power supply  260  (i.e. the source of V High ) and the output stage  240  and V High  is sensed for analysis. In an alternative embodiment (not illustrated), the inductor is placed between the output stage  240  and the load and V Load  is sensed for analysis.  FIG. 10  is a schematic representation of an exemplary DC signal V High  illustrating both a normal (i.e. non-short-circuit) and a short circuit condition. Instead of measuring the change in slope as in the AC application, the microprocessor  270  tests for a drop in voltage V High  to below a pre-defined threshold. Upon short circuit detection, the microprocessor  270  resets the “wait” timer to a non-zero value. 
         [0052]    In a further alternative embodiment for use in a DC application, no inductor is needed when the impedance of the power supply (i.e. the source of V High ) is sufficiently high so that the output stage  240  is not damaged during the brief period of the short-circuit analysis. 
         [0053]    The method according to the present invention can be implemented by a computer program product comprising computer executable instructions stored on a computer-readable storage medium. 
         [0054]    It will be apparent to one skilled in the art that numerous modifications and departures from the specific embodiments described herein may be made without departing from the spirit and scope of the present invention.