Programmable Current-Sensing Switch for Shared Tool Circuits
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Solution Overview
Problem
Existing power controller circuits in woodshops and machine shops are imprecise and lack fine control, often causing circuit breakers to trip due to current spikes from multiple devices operating on the same circuit, necessitating a more flexible switch for various situations and devices.
Innovation Solution
A variable control switch with a sensing circuit and microcontroller unit that adjusts current to primary and secondary devices based on pre-determined variables, including termination threshold, to prevent circuit breaker tripping by managing current spikes and delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power controller circuits are used to regulate current to multiple devices, then circuit breaker tripping is prevented, but control precision and flexibility are insufficient for various devices and situations
Solution Approach 1:
The patent implements dynamic control by allowing users to programmatically set and adjust multiple parameters including on-delay and off-delay timers, current thresholds, and hysteresis values. This enables the power controller to adapt its behavior dynamically based on specific device requirements and operational conditions, resolving the contradiction between reliable circuit protection and flexible adaptability to various devices
Solution Approach 2:
The invention changes multiple controllable parameters such as current thresholds, time delays, and hysteresis levels to optimize performance for different devices. By allowing programmable adjustment of these parameters, the system maintains reliable circuit breaker protection while providing the versatility needed for various power tools and equipment with different current profiles and operational requirements
2Productivity
If existing power controller circuits regulate current to multiple devices, then simultaneous device operation is enabled, but control precision lacks fine adjustment capability
Solution Approach 1:
The patent incorporates feedback mechanisms through programmable current threshold detection and hysteresis control. The system continuously monitors current draw and compares it against user-defined thresholds, providing precise control over when devices are activated or deactivated. This feedback-based approach enables fine-tuned current management that maintains high productivity through simultaneous device operation while achieving precise control measurement
Solution Approach 2:
The invention uses programmable on-delay timers that activate devices in advance according to predetermined time sequences. This preliminary action capability allows the system to manage current spikes by controlling the timing of device activation, enabling simultaneous operation of multiple devices with precise temporal control to prevent circuit breaker tripping
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 switch effectively manages current spikes and delays to prevent circuit breaker tripping, allowing multiple devices to operate safely without excessive downtime, enhancing control and precision in dynamic work environments.
Implementation Method 1
The sensing circuit has an output comprising DC voltage varying proportionally to the current passing between said first and second output plugs
Data Source
AI summary
The present invention is a variable control switch. In particular, it is a control switch with modifiable variables for activation and deactivation of primary and secondary devices. The control switch has an input plug and two output plugs. The control switch has a sensing circuit connected between the input plug and two output plugs and has an output comprising DC voltage varying proportionally to the current passing between said first and second output plugs. The sensing circuit is connected to a microcontroller unit that controls current to the first or second outputs based on a set of pre-determined variables, including a termination threshold.