Brushless DC Motor Power Supply Segmentation for Idle Energy Waste
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Solution Overview
Problem
Existing movable barrier opener systems with brushless motors face inefficiencies due to large, unnecessary power supplies that consume excess energy during idle periods, leading to waste and increased costs, as they are sized to handle peak power demands that occur intermittently during motor operation.
Innovation Solution
A power supply system with a separate drive circuit power module and storage bank that deactivates during non-use periods and uses the storage bank to provide power during peak demands, allowing for smaller, less expensive components and reducing quiescent power consumption by only activating when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large power supply is used to handle peak power demands, then the motor can operate during movement periods, but the power supply consumes excessive quiescent power during idle periods
Solution Approach 1:
The power supply system is segmented into two separate power supplies: a first power supply for the controller and a second power supply for the motor. This allows each power supply to be sized appropriately for its specific load, preventing the controller power supply from being oversized for idle periods while the motor requires high power during operation.
Solution Approach 2:
The system dynamically activates or deactivates the second power supply based on motor operation status. The controller receives signals indicating whether the motor is operating or not, and accordingly activates the second power supply only when needed, reducing quiescent power consumption during idle periods.
2Reliability
If a large power supply is used to handle maximum instantaneous current, then the motor can initiate movement and change direction, but the power supply components are unnecessarily large during rest time
Solution Approach 1:
The power supply system is divided into separate components for different functions: a first power supply for controller operation and a second power supply for motor operation. This segmentation allows each component to be optimized for its specific purpose, with the second power supply sized for peak motor current demands while the first power supply remains compact for controller needs.
Solution Approach 2:
The controller acts as an intermediary between the two power supplies and the motor. It manages power distribution, activates the second power supply only when motor operation is required, and ensures proper power sequencing, thereby enabling reliable motor operation without requiring a continuously active large power supply.
3Productivity
If the power supply is sized for maximum instantaneous current requirement, then the motor can operate during movement, but significant power is wasted during idle time between movements
Solution Approach 1:
The second power supply is dynamically controlled based on motor operation status. The controller activates the second power supply only when the motor needs to operate (during movement periods) and deactivates it during idle periods between movements, thereby eliminating wasted power consumption while maintaining full motor operation capability when needed.
Data Source
AI summary
A movable barrier opener system having a brushless DC motor is provided. The movable barrier opener system may have a power supply unit with a drive circuit power module and a storage bank. The storage bank may be chargeable by the drive circuit power module and may be connectable to the drive assembly to provide electrical power to the drive assembly to move the movable barrier. The drive circuit power module may be selectably turned on and off to improve efficiency of power consumption by turning off during periods of lowered demand.