Actuator Power Supply Architecture for Remote Operation
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Solution Overview
Problem
The existing actuator systems face high energy supply costs due to the requirement of a power pack for the control unit and primary energy supply, which can be inefficient, especially in remote or isolated locations with fluctuating power sources.
Innovation Solution
The actuator design incorporates a secondary energy supply for the drive motor, utilizing a lower-powered primary energy supply for the control unit, which can include a connection for a control line, photovoltaic system, or energy storage, allowing the actuator to operate independently and reduce the need for a power pack, with the energy store supporting the primary supply and providing peak power when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power pack is used to supply the control unit from the primary power supply, then the control unit receives sufficient power, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the power conversion function from a separate power pack component and integrates it directly into the control unit. The control unit now contains both the control logic and the power conversion circuitry, eliminating the need for an external power pack while maintaining the ability to convert primary power supply output to the required DC voltage for control operations
Solution Approach 2:
The control unit and power conversion functionality are merged into a single integrated component. This combination allows the control unit to directly convert and regulate power from the primary supply without requiring a separate power pack, thereby reducing overall device complexity while ensuring reliable power delivery
2Power
If a three-phase connection is used for the primary energy supply, then sufficient power is available for the drive motor, but the cost and complexity of energy supply infrastructure increases
Solution Approach 1:
The system dynamically adapts its power consumption based on operational needs. The control unit monitors the actuator state and adjusts its power draw accordingly, allowing the system to operate efficiently from lower-power single-phase supplies during idle or low-demand periods while maintaining the capability to utilize three-phase power when full motor performance is required
Solution Approach 2:
The invention changes the power supply parameter from fixed three-phase to variable configurations. The system can operate with single-phase, two-phase, or three-phase primary supplies depending on availability and requirement, with the control unit adapting its operation to match the supplied power configuration, thereby reducing infrastructure complexity while maintaining full power capability when needed
3Power
If a high-power primary energy supply is used, then the drive motor can be supplied with sufficient power, but the cost of the energy supply system increases
Solution Approach 1:
The control unit employs partial action by drawing only the necessary amount of power from the primary supply at any given moment rather than continuously operating at maximum capacity. The system activates power conversion and motor drive functions only when needed, allowing the use of lower-capacity, more cost-effective primary supply infrastructure while maintaining full motor performance during actual operation
Solution Approach 2:
The system uses periodic action through duty-cycled operation of the control unit and motor drive. Rather than continuous high-power operation, the control electronics activate in periodic bursts to manage motor operation, allowing the primary energy supply to be sized for average rather than peak demand, thereby reducing supply capacity requirements and associated costs
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
This design simplifies the actuator's energy supply, reduces costs, and enables operation in remote locations by using a lower-powered primary energy source, ensuring continuous and peak power delivery to the drive motor, even in areas with fluctuating energy sources.
Implementation Method 1
the actuator has at least one energy store (4) that can be charged via the primary energy supply (5)
Implementation Method 2
an actuator (1) with a drive motor (3)
Data Source
Figure 1~2
AI summary
An actuator (1) comprising a drive motor (3), a control unit (2), and a primary power supply (5) is characterized in that the primary power supply (5) serves to power the control unit (2) and that the actuator (1) has a secondary power supply (7) to power the drive motor (3). The secondary power supply (7) is, for example, an energy storage device (4) that can be charged via the primary power supply (5) or a mains connection (12). The actuator (1) can be designed as a single unit or in two parts.