Condensate Pump Low-Load Detection Using Phase-Cutting Control
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Solution Overview
Problem
Existing condensate collection systems in appliances like laundry drying machines and air conditioners face issues with high energy consumption and maintenance costs due to the use of float sensors for detecting low load conditions, which can lead to inefficient pump operation and potential overflowing.
Innovation Solution
A method for detecting low load conditions in a synchronous electric motor-driven pump that uses phase-cutting control to measure variations in firing angles and compares these variations to a predefined threshold, allowing for efficient operation without sensors and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float sensor is used to detect low load conditions, then the pump operation can be controlled, but the manufacturing cost increases and the device complexity increases
Solution Approach 1:
The patent replaces the mechanical float sensor system with an electrical detection system. The control board detects pump load conditions by monitoring electrical parameters (current, power consumption) of the motor-driven pump, eliminating the need for mechanical float sensors and their associated cabling. This substitution reduces device complexity while maintaining operational control reliability.
Solution Approach 2:
The pump system performs self-detection of its own load conditions through the control board monitoring electrical parameters. The system uses its own operational characteristics (electrical consumption patterns) to determine when the condensate tank is full or when the pump is running dry, eliminating the need for separate detection components.
2Reliability
If a float sensor is used to detect low load conditions, then the pump operation can be controlled, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical float sensor system with an electrical detection system. The control board detects pump load conditions by monitoring electrical parameters (current, power consumption) of the motor-driven pump, eliminating the need for mechanical float sensors and their associated cabling. This substitution reduces device complexity while maintaining operational control reliability.
Solution Approach 2:
The pump system performs self-detection of its own load conditions through the control board monitoring electrical parameters. The system uses its own operational characteristics (electrical consumption patterns) to determine when the condensate tank is full or when the pump is running dry, eliminating the need for separate detection components.
3Productivity
If the pump is activated for a predetermined time interval, then the bottom tank can be emptied, but the energy consumption increases when the tank is already empty
Solution Approach 1:
The control board continuously monitors the pump's electrical parameters during operation and uses this feedback to detect when the pump is running dry (empty tank condition). When the feedback indicates zero or minimal load, the system immediately interrupts pump operation, preventing unnecessary energy consumption while ensuring complete tank emptying when liquid is present.
Solution Approach 2:
The patent transitions from a static, fixed-duration pump activation scheme to a dynamic control system that continuously adjusts pump operation based on real-time load detection. The pump runs for the necessary duration to empty the tank, then automatically stops when the empty condition is detected, optimizing energy usage according to actual operational needs.
4Device complexity
If the pump operates with a fixed activation time, then the control is simple, but the energy consumption is high and the productivity decreases
Solution Approach 1:
The control board continuously monitors the pump's electrical parameters during operation and uses this feedback to detect when the pump is running dry (empty tank condition). When the feedback indicates zero or minimal load, the system immediately interrupts pump operation, preventing unnecessary energy consumption while ensuring complete tank emptying when liquid is present.
Solution Approach 2:
The patent transitions from a static, fixed-duration pump activation scheme to a dynamic control system that continuously adjusts pump operation based on real-time load detection. The pump runs for the necessary duration to empty the tank, then automatically stops when the empty condition is detected, optimizing energy usage according to actual operational needs.
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 method effectively determines low load conditions without sensors, reducing energy consumption and maintenance costs, and prevents overflowing by accurately interrupting pump operation when the condensate collection system is full, thereby ensuring efficient condensate collection.
Implementation Method 1
a feedback setpoint thereof being a condition of minimum phase-shift between current supplying the windings of the electric motor and generated counter-electromotive force
Data Source
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AI summary
Method (400) for detecting a low load condition of a pump actuated by a synchronous electric motor, comprising the following steps: - steady-state driving of said electric motor (1) by means of phase-cutting control, a feedback setpoint thereof being a condition of minimum phase-shift between current supplying the windings of the electric motor (1) and generated counter-electromotive force; - detecting (430, 440) at least two firing angles (α0, α1) successively applied, in relation to said phase-cutting control, during two successive half-periods of a voltage supplying the electric motor; - calculating (450) at least one variation (Δα) between two consecutive firing angles (α0, α1) previously detected; - comparing (490) said variation (Δα), or the sum of said successive variations (∑Δα), with a threshold value (Δαmax), where reaching or exceeding said threshold value (Δαmax) identifies said low load condition.