High efficiency hydronic circulator with sensors
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Solution Overview
Problem
Existing hydronic heating and cooling systems face inefficiencies due to over-circulation, noise, and high costs associated with rare earth magnet rotors and trapezoidal control strategies, which result in excessive energy usage and maintenance requirements.
Innovation Solution
A stand-alone circulator system utilizing a ferrite permanent magnet rotor with sinusoidal commutation and a variable frequency drive (VFD) powered by rectified AC voltage, controlled by thermal sensors to optimize flow output and reduce noise and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a rare earth magnet rotor with trapezoidal control is used, then the motor achieves relatively high efficiency, but it produces excessive noise and requires costly materials
Solution Approach 1:
The patent changes the control waveform parameter from trapezoidal to sinusoidal, and changes the magnet material parameter from rare earth to ferrite. This dual parameter change resolves the contradiction by eliminating the high-frequency switching noise inherent in trapezoidal control while maintaining motor efficiency through optimized sinusoidal commutation tailored to ferrite magnet characteristics.
2Use of energy by moving object
If a rare earth magnet rotor is used, then the motor achieves relatively high efficiency, but it results in high cost
Solution Approach 1:
The patent substitutes expensive rare earth magnets with cheaper ferrite magnets. Although ferrite magnets have lower inherent magnetic strength, the system compensates through optimized sinusoidal control and appropriate magnet sizing, achieving comparable efficiency at significantly reduced material cost.
3Use of energy by moving object
If a step-down transformer is used to provide 12V DC power, then the motor operates at low voltage, but it incurs initial cost and maintenance losses
Solution Approach 1:
The patent extracts and eliminates the step-down transformer from the power supply system by implementing direct sinusoidal control from rectified line voltage. This removes the transformer's initial cost, maintenance requirements, and energy losses while providing sufficient voltage for the ferrite magnet motor operation.
4Adaptability or versatility
If thermal sensors continuously send data to a programmable PCB, then the circulator can adjust flow output, but it requires complex control circuitry and increases cost
Solution Approach 1:
The patent implements a self-service control approach where the sinusoidal commutation controller directly processes thermal sensor inputs and autonomously adjusts motor speed and flow output without requiring complex programmable logic. The system serves itself by integrating sensing and control functions in a simplified architecture.
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 system achieves improved efficiency, reduced noise, and lower operational costs by using a ferrite magnet rotor with sinusoidal control, allowing for precise flow adjustments and minimizing energy usage while maintaining system performance.
Implementation Method 1
an electrically powered, rotary motor, controlled by an electronic, variable frequency drive (VFD) control system for controlling the speed of the motor by varying the frequency of the rectified DC current supplied to power the stator coils of the motor
Implementation Method 2
a system of stator coils powered by a non-stepped down, sinusoidally varying DC voltage from a rectified AC power supply, i.e. either a 115-120V AC rectified to about 170 Volts DC or a 230-240V AC, rectified to about 340 Volts DC
Implementation Method 3
controlled by an electronic, variable frequency drive (VFD) control system for controlling the speed of the motor by varying the frequency of the rectified DC current supplied to power the stator coils of the motor
Implementation Method 4
controlled by at least one thermal sensor placed in the flow conduits of the hydronic system, that provides data allowing the pump controller to determine the optimal output flow of the pump under specific temperature differential conditions
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
A highly efficient circulator system is provided, useful for hydronic systems, including both heating and cooling systems. The stand-alone circulator motor is controllable by input from certain sensors, preferably thermal sensors, which provide data enabling the controller of the brushless pump motor to vary its flow output to meet changes in systems loads. The circulator has a ceramic permanent magnet rotor, such as a ferrite, with an electronically, preferably sinusoidally, commutated, electro-magnetic stator controlling the input of electrical power.