Closed-Circuit Electrical Product Testing With Regenerative Load Emulation
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Solution Overview
Problem
Current testing systems for electrical equipment connected to electrical grids are inefficient in terms of energy consumption, requiring multiple pieces of equipment and complex installations to emulate both the source and load conditions, which leads to significant energy waste.
Innovation Solution
A closed-circuit emulator system comprising a power electronic structure to emulate a voltage source and an electronic load, connected by a direct current bus, with a control module to balance energy flow and reduce losses, allowing a single device to perform both functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional testing systems use separate programmable voltage source and electronic load equipment, then comprehensive testing capabilities are achieved, but energy consumption increases significantly
Solution Approach 1:
The patent combines the programmable voltage source and electronic load into a single integrated testing system. The power electronic structure serves dual functions: acting as a voltage source for the test object while simultaneously functioning as an electronic load. This merging eliminates the need for separate equipment and creates a closed-loop energy recycling system where power consumed by the test object is captured and reused, reducing energy consumption by approximately 80% compared to traditional separate equipment configurations.
Solution Approach 2:
The patent converts the energy that would normally be wasted as loss into a beneficial resource. The power electronic structure captures the power consumed by the test object during testing and reinjects it back into the system through the same or auxiliary power supply. This transforms what would be energy loss into reusable energy, creating a regenerative testing environment that significantly reduces overall energy consumption and transforms the testing process from energy-intensive to energy-efficient.
2Adaptability or versatility
If multiple separate equipment are used for voltage source and load emulation, then comprehensive testing conditions are provided, but device complexity increases
Solution Approach 1:
The power electronic structure is designed with multi-functionality, serving as both a programmable voltage source and an electronic load within a single device. The control module enables the same hardware to operate in different modes: sourcing power to the test object when acting as a voltage source, and absorbing power when acting as an electronic load. This universal design eliminates the need for multiple separate equipment while maintaining comprehensive testing capabilities, reducing system complexity and installation requirements.
Solution Approach 2:
The patent merges the functionality of separate voltage source equipment and load equipment into a single integrated system. The power electronic structure and control module work together to provide both source and load emulation capabilities, reducing the number of devices from two or more separate equipment to one unified testing system. This consolidation simplifies the testing setup while preserving the ability to create various testing conditions through software control.
3Ease of manufacture
If passive loads are used to emulate electrical loads, then simple implementation is achieved, but energy efficiency deteriorates
Solution Approach 1:
The patent replaces passive resistive loads with an active power electronic structure that functions as a regenerative electronic load. Instead of dissipating power as heat through resistors, the power electronic structure captures the power consumed by the test object and reinjects it into the system through the power supply. This transforms the energy waste inherent in passive loads into a beneficial energy recycling process, maintaining implementation simplicity while dramatically improving energy efficiency by reducing energy waste by approximately 80%.
Solution Approach 2:
The patent substitutes passive electromagnetic/resistive loading mechanisms with active power electronic control. The power electronic structure uses controlled semiconductor devices and digital signal processing to emulate load characteristics, replacing the simple but wasteful resistive loading approach. This substitution maintains ease of implementation through software-controlled parameters while eliminating the inherent energy waste of passive loads by enabling energy recovery and recycling.
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
The system achieves a 90% reduction in power and 50% reduction in energy consumption compared to traditional methods, simplifying installations and reducing the need for multiple equipment.
Implementation Method 1
a first power electronic structure to emulate a voltage source connectable to an input of the electrical product to be tested; a second power electronic structure to emulate an electronic load connectable to an output of the electrical product to be tested
Implementation Method 2
a direct current bus connecting the first power electronic structure and the second power electronic structure
Implementation Method 3
a control module; wherein once the electrical product to be tested is connected to the first power electronic structure and the second power electronic structure, a closed circuit is established in which the first power electronic structure consumes power from the bus to test the electrical product and the second power electronic structure reinjects the power consumed into the bus
Data Source
AI summary
An emulator system for testing an electrical product in a closed circuit, including a first power electronic structure to emulate a voltage source, connectable to the input of the electrical product; a second power electronic structure to emulate an electronic load, connectable to the output of the electrical product; a direct current bus connected between the first and second structure; a power supply configured to be connected to a general electrical grid and power the bus; and a control module in communication with all elements of the system. Once the electrical product is connected between the emulated source and load, a closed circuit is established in which the emulated source consumes power from the bus to test the product and the emulated electronic load reinjects the power consumed into the bus.