Digital power supply
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Solution Overview
Problem
Existing power supplies for high-powered loads, such as electric grills, fail to provide precise control over multiple heating elements while introducing significant harmonics and flicker into the power system, leading to inefficient energy use and reduced heating element lifespan.
Innovation Solution
A digital power supply system that uses a microprocessor to calculate and deliver phase-controlled AC wave patterns to multiple heating elements, allowing independent control and reducing harmonic currents and flicker by using triacs and zero crossing detection to manage power delivery, ensuring compliance with harmonic and flicker regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If variable resistors are used to control power delivery to electric loads, then power control is achieved, but harmonics are introduced onto the electrical system and power efficiency decreases
Solution Approach 1:
The patent replaces mechanical variable resistors with solid-state triac-based phase angle control circuitry. This substitution eliminates the need for physical resistance adjustment while achieving precise power control through electronic timing control of triac firing angles, thereby reducing harmonic distortion and improving power efficiency.
Solution Approach 2:
The patent changes the control parameter from resistance value adjustment to phase angle timing control. By varying the firing angle of triacs relative to the AC waveform zero-crossing points, the system achieves continuous power control without the harmonic issues associated with variable resistors.
2Device complexity
If bi-metal thermometers are used to control power delivery, then simple control is achieved, but response time increases and control precision decreases
Solution Approach 1:
The patent replaces mechanical bi-metal thermometer actuators with digital microprocessor-based control systems. This substitution eliminates thermal lag inherent in bi-metal mechanisms by using electronic temperature sensing and digital processing to achieve immediate response and precise control.
Solution Approach 2:
The patent introduces a microprocessor as an intermediary between temperature sensing and power control. This intermediary processes temperature data in real-time and generates precise triac control signals, eliminating the slow mechanical response of bi-metal thermometers while maintaining simple overall system architecture.
3Ease of operation
If half-wave control techniques are used to deliver power, then power delivery control is achieved, but continuous variable power delivery from 0-100% is not possible
Solution Approach 1:
The patent implements dynamic phase angle control where the triac firing angle can be continuously adjusted throughout each AC cycle. This dynamic control allows seamless variation of power delivery from 0% (firing angle at peak) to 100% (firing angle at zero-crossing), providing continuous adaptability that half-wave control cannot achieve.
Solution Approach 2:
The patent uses periodic AC waveform analysis with zero-crossing detection to establish precise timing intervals for triac firing. By controlling the phase angle within each periodic AC cycle, the system achieves continuous power variation while maintaining synchronization with the power supply frequency.
4Ease of operation
If multiple electric loads are controlled independently, then precise power control for each load is achieved, but harmonic currents and flicker are introduced into the power system
Solution Approach 1:
The patent incorporates zero-crossing detection feedback to synchronize all triac control operations with the AC power supply waveform. This feedback mechanism ensures that independent control of multiple loads does not create phase conflicts or harmonic interference, as all controls are referenced to the same timing基准.
Solution Approach 2:
The patent implements a universal control architecture where a single microprocessor manages multiple triac channels with independent phase angle control. This multi-functional system achieves independent load control while using common timing references and control algorithms to minimize harmonic currents and flicker across all channels.
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
Enables precise power control for multiple heating elements, reduces harmonic currents and flicker, and extends the lifespan of heating elements by providing continuous variable power delivery within the 0-100% range, ensuring compliance with regulatory standards.
Implementation Method 1
causing the microprocessor to receive a zero crossing signal from a zero crossing detection unit
Implementation Method 2
delivering a phase-controlled AC wave pattern represented by the first phase angle array to the first heating element and delivering a phase-controlled AC wave pattern represented by the second phase angle array to the second heating element
Data Source
AI summary
Provided is an apparatus and method for a digital power supply that can provide independent power control, and control variable power, for two or more electrical loads. Disclosed embodiments may reduce the magnitude of harmonic currents and/or flicker introduced into a power system. Embodiments include a microprocessor that delivers power to electric loads using phase-controlled AC current. The microprocessor may calculate a power array corresponding to a requested power for each electric load. Logic is provided for populating the power army in a pattern that reduces the magnitude of harmonic currents and flicker.