High efficiency hydronic circulator with sensors
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Solution Overview
Problem
Existing hydronic system circulators are inefficient, noisy, and costly due to their reliance on rare earth magnets and trapezoidal control strategies, which result in excessive energy consumption and noise.
Innovation Solution
A highly efficient stand-alone wet rotor circulator system using a ferrite permanent magnet rotor and a sinusoidally commutated electromagnetic stator, powered by a variable frequency drive (VFD) system, which allows for optimal flow control based on thermal sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If rare earth magnets and trapezoidal control strategy are used, then motor efficiency is improved, but noise increases and cost increases
Solution Approach 1:
The patent changes the control strategy from trapezoidal to sinusoidal commutation and switches from rare earth magnets to ferrite magnets. This parameter change in the control waveform and magnet material reduces noise while maintaining efficiency through optimized current waveforms that produce smoother motor operation.
Solution Approach 2:
The patent substitutes expensive rare earth magnets with cheaper ferrite magnets. While ferrite magnets are less powerful, the sinusoidal control strategy compensates for this by optimizing the electromagnetic interaction, achieving comparable efficiency at lower cost and noise levels.
2Loss of energy
If rare earth magnets and trapezoidal control strategy are used, then motor efficiency is improved, but cost increases
Solution Approach 1:
The patent replaces expensive rare earth magnets with inexpensive ferrite magnets. The cost reduction is achieved by using abundant, low-cost ferrite material while compensating for its lower magnetic strength through sinusoidal control optimization, resulting in lower manufacturing costs without sacrificing efficiency.
Solution Approach 2:
The patent changes the control waveform from trapezoidal to sinusoidal, which allows the use of cheaper ferrite magnets to achieve the same efficiency. The sinusoidal control optimizes the electromagnetic interaction to maximize the utilization of the ferrite magnet's magnetic field, reducing the need for expensive rare earth materials.
3Temperature
If step-down transformer is used, then voltage is reduced, but operating power losses increase and initial cost increases
Solution Approach 1:
The patent extracts and eliminates the step-down transformer from the system by implementing direct sinusoidal control of the motor at line voltage. This removes the transformation step that caused power losses, allowing the motor to operate efficiently at higher voltage with reduced current and associated losses.
Solution Approach 2:
The patent replaces the mechanical/electrical transformation system (transformer) with an electronic control system that generates sinusoidal waveforms directly at the motor. This substitution eliminates the physical transformer and its associated power losses while maintaining voltage control through electronic means.
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 significant energy savings, reduced noise, and improved efficiency by electronically modulating speed and using a ferrite magnet rotor, while also eliminating the need for a step-down transformer.
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 ferrite permanent magnet rotor is used, together with a system of stator coils powered by a non-stepped down, sinusoidally varying DC voltage
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.