Low Power Logic Circuit for Reliable High Power Device Disabling

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Solution Overview

Problem

High power devices, such as motors, pose hazards during maintenance and require reliable disabling methods to prevent accidents, but existing technologies like high power contactors are expensive, bulky, and inefficient.

Innovation Solution

A drive circuit design that includes a high power section and a low power logic section, where the low power section controls the high power section by providing disabling signals to cease power delivery to the load, using mechanisms like safety relays and redundant logic circuits to ensure reliable shutdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high power contactors are used to disable high power devices, then reliability of disabling is improved, but device complexity, cost, and physical size increase

Engineering Contradiction:
Improvereliability of disablingVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a low-power intermediary circuit that acts as a mediator between the control system and the high-power load. This intermediary circuit uses low-power transistors and logic circuits to control the high-power devices, eliminating the need for bulky high-power contactors while maintaining reliable disabling capability. The intermediary circuit receives low-power control signals and uses them to switch the high-power load, thereby resolving the contradiction between reliability and device complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical high-power contactor system with an electronic control system using low-power transistors and logic circuits. Instead of using mechanical contacts that require physical movement and are bulky, the invention uses electronic switching devices that can be controlled by low-power signals. This substitution eliminates the mechanical complexity and physical size of contactors while maintaining the ability to reliably disable high-power devices.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high power contactors are used to disable high power devices, then reliability of disabling is improved, but cost increases

Engineering Contradiction:
Improvereliability of disablingVSAvoidcost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The low-power intermediary circuit serves as a cost-effective mediator that eliminates the need for expensive high-power contactors. By using low-power transistors and logic circuits that are inexpensive and easily manufactured, the system achieves reliable disabling functionality at a lower cost. The intermediary circuit translates low-cost low-power control signals into effective high-power switching actions.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses low-power logic circuits that replicate or copy the control functionality of high-power contactors but at a much lower cost. The low-power circuitry implements the same disabling logic and control functions using inexpensive electronic components rather than expensive mechanical contactors, thereby reducing manufacturing cost while maintaining reliability.

Inventive Principle:
Principle #26Copying

3Reliability

If high power contactors are used to disable high power devices, then reliability of disabling is improved, but connection and disconnection time increases

Engineering Contradiction:
Improvereliability of disablingVSAvoidconnection and disconnection time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical switching mechanism of high-power contactors with electronic switching using low-power transistors. Electronic switching occurs almost instantaneously compared to mechanical contactors that require physical movement of contacts. This substitution maintains reliable disabling capability while dramatically reducing the time required for connection and disconnection operations.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention introduces dynamic electronic control that can switch states instantaneously in response to control signals. The low-power logic circuits and transistors can change state almost immediately when commanded, providing rapid connection and disconnection capabilities. This dynamic response eliminates the mechanical inertia and contact movement time inherent in traditional high-power contactors.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS8593768B2Apparatus and method for disabling the operation of high power devices
Publication Date: 2013.11.26 ROCKWELL AUTOMATION TECH INC
  • US8593768B2 patent drawing
  • US8593768B2 patent drawing
  • US8593768B2 patent drawing

AI summary

A drive circuit for delivering high-level power to a load, and method of stopping a high power load from operating, are disclosed. The drive circuit includes a high power circuit capable of being coupled to the load and delivering the high level power thereto, and a low power circuit that controls the high power circuit. The low power circuit includes a first circuit portion that provides at least one control signal that is at least indirectly communicated to the high power circuit and that controls the delivering of the high level power by the high power circuit, and a second circuit portions coupled to the first circuit portion. The second circuit portion is capable of disabling the first circuit portion so that the at least one control signal avoids taking on values that would result in the high power circuit delivering the high level power to the load.