High efficiency circulator with sensors
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Solution Overview
Problem
Existing hydronic heating and cooling systems using rare earth magnet rotors and trapezoidal control strategies are costly, noisy, and inefficient, with prior art circulators often overcirculating and wasting energy due to inadequate response to thermal demands.
Innovation Solution
A circulator system utilizing a ferrite permanent magnet rotor and sinusoidally commutated stator, powered by rectified AC voltage, controlled by thermal sensors and a VFD system to adjust flow based on system loads, reducing 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 motor efficiency is improved, but noise increases and cost increases
Solution Approach 1:
The patent changes the control waveform parameter from trapezoidal to sinusoidal, and switches from DC voltage to rectified AC voltage. This parameter change maintains motor efficiency while significantly reducing noise levels, making the circulator suitable for residential environments.
Solution Approach 2:
The patent replaces expensive rare earth magnets with more economical ferrite magnets. While ferrite has lower magnetic strength, the combination with rectified AC power and sinusoidal control compensates for this, achieving comparable efficiency at lower cost.
2Use of energy by moving object
If a rare earth magnet rotor with trapezoidal control is used, then motor efficiency is improved, but cost increases
Solution Approach 1:
The patent substitutes expensive rare earth magnets with inexpensive ferrite magnets. The lower magnetic strength of ferrite is compensated by using rectified AC power and sinusoidal control, achieving cost reduction without sacrificing efficiency.
Solution Approach 2:
The patent changes the power input from low voltage DC to high voltage rectified AC, and the control waveform from trapezoidal to sinusoidal. These parameter changes enable the use of cheaper ferrite magnets while maintaining motor efficiency.
3Loss of energy
If thermal sensors control the circulator speed, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The patent uses thermal sensors to continuously monitor temperature differentials and provides feedback to the controller. The controller adjusts circulator speed based on this feedback, optimizing energy efficiency while maintaining relatively simple system architecture through straightforward sensor-controller actuator linkage.
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 efficient, quiet operation with reduced energy usage and improved thermal response, minimizing noise and energy waste by dynamically adjusting flow rates to meet thermal demands.
Implementation Method 1
an electronically, preferably sinusoidally commutated, electro-magnetic stator controlling the input of electrical power
Implementation Method 2
a molded, ceramic, such as a ferrite, permanent magnet rotor
Implementation Method 3
a system of stator coils powered by a non-stepped down, sinusoidally varying DC voltage from a rectified AC power supply
Data Source
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.