Dispenser Power Management Using Zero Net Voltage to Reduce Corrosion
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Solution Overview
Problem
Existing dispensing systems face challenges with battery management, including inefficient power transfer, corrosion at electrical interfaces, and the need for frequent battery replacements, which leads to operational inefficiencies and increased maintenance costs in humid environments.
Innovation Solution
A power management system utilizing a controller connected to a zero net voltage (ZNV) power source with a power rectification circuit to convert ZNV power to higher voltage direct current (HVDC) for energy storage, which is selectively directed to a dispenser load, minimizing corrosion and optimizing power delivery through capacitors and auxiliary power cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a single or multiple batteries are used to provide energy to complete a dispensing cycle, then the dispenser can operate automatically, but the batteries require frequent replacements which increases maintenance costs and operational inefficiency
Solution Approach 1:
The power source is divided into multiple separate batteries (first battery and second battery) that can be independently replaced. This segmentation allows individual battery replacement rather than replacing the entire power system, reducing maintenance time and operational disruption.
Solution Approach 2:
The system includes a battery replacement mechanism that can be activated before the batteries are completely depleted. The controller monitors battery status and enables proactive replacement, preventing operational failures and reducing downtime by addressing power needs before complete exhaustion occurs.
2Power
If traditional electrical contacts are used to transfer power from batteries to the dispenser motor, then power can be delivered, but corrosion occurs at the electrical interface particularly in humid environments
Solution Approach 1:
The system replaces traditional continuous electrical contacts with a mechanical switching mechanism. The switch is actuated by the dispenser motor itself during normal operation, eliminating the need for continuous sliding contacts that are susceptible to corrosion. This mechanical substitution reduces corrosion while maintaining power delivery capability.
Solution Approach 2:
Instead of continuous electrical contact, the system uses periodic electrical connection through the switch mechanism. The switch closes temporarily during dispensing cycles to transfer power, then opens. This periodic action reduces cumulative corrosion exposure compared to continuous contact while delivering the necessary power.
3Reliability
If batteries are replaced frequently to maintain operational reliability, then users experience fewer disruptions, but maintenance costs and personnel time increase significantly
Solution Approach 1:
The power system is segmented into multiple batteries that can be independently managed and replaced. This allows partial replacement scenarios where only one battery needs changing rather than the entire power system, reducing maintenance costs and personnel time while maintaining operational reliability through redundant power sources.
Solution Approach 2:
The system includes automated battery monitoring and status indication that enables users to identify when battery replacement is needed without requiring specialized maintenance personnel. The controller provides visual or electronic alerts, allowing facility users to perform simple battery replacements themselves, reducing personnel time and maintenance costs.
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 system enhances power transfer efficiency, reduces corrosion, and minimizes the need for frequent battery replacements, ensuring reliable operation and reducing maintenance costs by effectively managing power delivery and storage within dispensing systems.
Implementation Method 1
A power rectification circuit (PRC) converts ZNV power to higher voltage direct current (HVDC) power
Implementation Method 2
An energy storage system connected to the HVDC power source receives and stores HVDC power within the energy storage system
Data Source
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AI summary
A power management system for dispensers is described. The system includes a controller connected to a lower power zero net voltage (ZNV) power source. A power rectification circuit (PRC) converts ZNV power to higher voltage direct current (HVDC) power. An energy storage system connected to the HVDC power source receives and stores HVDC power within the energy storage system which is selectively provided to a dispenser motor load connected to the energy storage system. The system provides an effective solution to the problem of transferring power from a low power battery source on a disposable product to a dispenser as well as providing a system that minimizes corrosion at the electrical interface between the disposable product and the dispenser particularly in higher humidity environments.