Heat Exchange Cooler Power Circuit With Automatic Tap Switching
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Solution Overview
Problem
Conventional heat exchange coolers face reliability and cost issues due to temperature sensitivity and complex wiring, and power circuit driving devices experience high-frequency noise radiation and manual tap switching challenges, leading to increased installation time and potential errors.
Innovation Solution
The implementation of sensor-less DC brushless motors for both indoor and outdoor fans, along with a commercial power transformer with automatic tap switching and output voltage detection, reduces temperature sensitivity, eliminates noise radiation, and automates voltage adjustments, thereby enhancing reliability and reducing installation time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic sensors (Hall elements) are installed in outdoor DC brushless motors for temperature sensing, then temperature control accuracy is improved, but the motors become sensitive to low-temperature environments and require installation in locations with ambient temperature above -30°C
Solution Approach 1:
The magnetic sensor (Hall element) is extracted and removed from the outdoor DC brushless motor. Instead of using a magnetic sensor within the motor to detect temperature, the patent uses sensor-less control that relies on current detection and computational models to estimate rotor position and temperature, thereby eliminating the component that fails in low-temperature environments.
Solution Approach 2:
The mechanical/magnetic sensing system (Hall element) is replaced with an electronic computational system. The patent employs sensor-less control algorithms that use current waveforms, voltage measurements, and mathematical models to infer rotor position and temperature without physical sensors, substituting direct magnetic measurement with computational estimation.
2Adaptability or versatility
If long relay leads are used to connect outdoor DC brushless motors with electronic control units, then motor control flexibility is improved, but signal noise interference increases and faulty operation occurs
Solution Approach 1:
The sensor signal lead is extracted and eliminated from the system. By removing the magnetic sensor, the long relay lead carrying sensor signals is no longer needed. The patent uses sensor-less control where rotor position information is obtained through current detection and computational algorithms rather than physical sensor leads.
Solution Approach 2:
An intermediary computational system is introduced between the motor and control unit. Instead of directly transmitting sensor signals through long leads, the patent uses current waveforms as an intermediary carrier of rotor position information, processed through mathematical models and algorithms to extract position data without requiring dedicated sensor signal paths.
3Adaptability or versatility
If manual tap switching is implemented in power circuit driving devices, then voltage adjustment flexibility is improved, but installation time increases and installation errors occur
Solution Approach 1:
The power circuit driving device performs self-service by automatically detecting input voltage levels and selecting appropriate transformer taps without manual intervention. The system uses voltage detection circuits to monitor input voltage and automatically switches transformer taps to maintain optimal output voltage, eliminating the need for installers to manually configure voltage settings.
Solution Approach 2:
A feedback mechanism is implemented where the power circuit continuously monitors input voltage levels and automatically adjusts transformer tap selection accordingly. The voltage detection circuit provides feedback about input voltage conditions, and the control system responds by selecting the appropriate tap configuration to maintain stable output voltage across varying input conditions.
4Use of energy by moving object
If high-frequency switching power circuits are used for power conversion, then power conversion efficiency is improved, but high-frequency noise radiation increases
Solution Approach 1:
The patent converts the harmful high-frequency noise radiation into a beneficial filtering opportunity. By using a transformer with higher frequency characteristics, the system generates high-frequency noise that is then effectively filtered by the transformer's inherent inductance and capacitance, transforming the harmful radiation into a controlled electromagnetic field that aids in noise suppression rather than causing interference.
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 solution provides a reliable, cost-effective heat exchange cooler that operates across varying temperatures without magnetic sensors, reduces noise interference, and automates voltage adjustments, resulting in a more efficient and less labor-intensive installation process.
Implementation Method 1
heat exchanging element 105 for exchanging sensible heat of the outside air and inside air
Implementation Method 2
air is passed through heat exchanging element 105
Implementation Method 3
indoor DC brushless motor 103 and outdoor DC brushless motor 107
Implementation Method 4
a pole sensor such as a Hall element
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
A heat exchange cooler capable of eliminating continuous radiation of high-frequency noise waves and reducing the man hour for the installation work, and a power circuit driving device used for it are provided. A commercial power transformer (311), which transforms commercial AC power (307) supplied from a heat generating element storing box to a specified range of voltage, is provided. Moreover, first relay (210) and second relay (212) are used for automatically switching a plurality of taps disposed at the coil of commercial power transformer (311) which keeps a wide range of commercial AC voltage from 200V to 250V in nominal voltage within a specified range of output voltage.