Compact Power Control Unit for Thermal Management

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Solution Overview

Problem

Existing power control systems for thermal control are complex, costly, and prone to premature component failures due to environmental degradation, limiting their flexibility and re-programmability, especially in harsh operating conditions, leading to costly downtime and reduced process yields.

Innovation Solution

A compact power control system with an integrated power switch, limiter, and controller housed in a controller unit that can be placed near the power load, featuring a safety limiter with multiple threshold temperature limits, allowing for programmable thermal control and reduced exposure to conductive heating effects, enabling efficient installation and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If discrete components are used for power control installations, then functionality can be achieved, but device complexity and installation cost increase

Engineering Contradiction:

ImprovefunctionalityVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the power switch, limiter, and controller into a single integrated power control unit. This merging of previously discrete components reduces installation complexity while maintaining all necessary functionalities including power switching, temperature limiting, and control capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated power control unit serves multiple functions simultaneously: it acts as a power switch, temperature limiter, and controller all in one device. This multi-functionality eliminates the need for separate discrete components, thereby reducing overall system complexity and installation requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If thermal fuse is used for protection, then safety is provided, but reliability decreases due to premature failure

Engineering Contradiction:

Improveprotection reliabilityVSAvoidenvironmental degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a controller as an intermediary between the power source and load, which monitors temperature and controls power switching. This intermediary approach replaces the passive thermal fuse with an active electronic control system that can respond to temperature conditions without suffering from the same environmental degradation issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical thermal fuse system with an electronic control system comprising a controller and power switch. This substitution eliminates the reliability issues associated with thermal fuses while maintaining safety through electronic temperature monitoring and control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of repair

If system shutdown is required for component replacement or recalibration, then maintenance can be performed, but productivity decreases

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidoperational continuity

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The integrated power control unit is designed to be mounted near the power load in the operating environment, allowing for easy access and maintenance without requiring complete system shutdown. The compact integrated design enables maintenance personnel to service the unit while the rest of the system remains operational.

Inventive Principle:

Principle #25Self-service

4Reliability

If controller is placed远离 power load, then electronics are protected from harsh environment, but response time and control effectiveness worsen

Engineering Contradiction:

Improveelectronics protectionVSAvoidcontrol response time

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The patent combines the controller with the power switch and limiter in a single integrated unit that is mounted near the power load. This merging allows the electronics to be positioned in the operating environment for fast response while the integrated housing provides protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated power control unit employs a housing that protects the electronic components from the harsh operating environment. This protective enclosure allows the controller to be mounted near the power load without exposing the electronics to damaging conditions, thus maintaining both fast response time and component protection.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS8044329B2Compact limiter and controller assembly and method

Publication Date: 2011.10.25 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A power control system has a controller housing, a power switch disposed within the controller housing for selectively providing power from a power supply to a power load, a limiter disposed within the controller housing configured for providing a limit switching function in response to a threshold limit, and a controller disposed within the controller housing and configured for controlling one or more operations of the control system.