Motor Actuated Relay for Automatic UPS Battery Reconnection
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Solution Overview
Problem
Manual reconnection of battery packs in UPS systems is prone to human error, leading to potential deep discharge and reduced runtime due to the need for operators to manually reset multiple switches after a power loss.
Innovation Solution
A UPS system with a power relay mechanism incorporating a motor actuator controlled by control circuitry that automatically reconnects the battery pack to the power circuitry when AC power is restored, using criteria such as timer expiration and safety conditions to manage the power relay mechanism's position, thereby reducing human intervention and error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual reconnection of battery packs is used, then the UPS system can be reset by operators, but human error leads to deep discharge and reduced runtime
Solution Approach 1:
The system automatically monitors power restoration conditions and actuates the relay mechanism without human intervention. The control circuitry detects when AC power is restored and automatically closes the relay to reconnect the battery pack, eliminating the need for manual operator intervention and preventing human error that causes deep discharge and reduced runtime.
Solution Approach 2:
The control circuitry continuously monitors the power source status and provides feedback control to the relay actuator. When the monitored AC power status changes from absent to restored, the system automatically actuates the relay mechanism to close the circuit and reconnect the battery pack to the power converter circuitry, ensuring reliable reconnection based on real-time power conditions.
2Ease of operation
If manual switching is used, then operators can control power flow, but the process is tedious and prone to error
Solution Approach 1:
The relay mechanism with motor actuator automatically performs the switching operation based on power restoration detection, eliminating the tedious manual process of locating and resetting multiple switches. The system self-manages the reconnection process by monitoring power status and automatically actuating the relay, making operation simple while maintaining high reliability through automated control logic.
Solution Approach 2:
The manual mechanical switching operation is replaced by an automated electromechanical relay mechanism controlled by electronic circuitry. The motor actuator automatically actuates the relay to close the circuit when power is restored, replacing the manual mechanical process with an automated electro-mechanical system that eliminates human error and simplifies operation.
3Reliability
If automated reconnection is implemented, then human error is reduced, but the device complexity increases
Solution Approach 1:
The control circuitry monitors the power source status and provides feedback control to the relay actuator, automatically actuating the relay when AC power is restored. This feedback-based automated control improves reliability by eliminating human error in reconnection while managing complexity through a straightforward monitor-and-actuate control logic that directly responds to power status changes.
Solution Approach 2:
The relay mechanism serves multiple functions: it controls power flow during normal operation, enables automatic reconnection when power is restored, and can be integrated with existing UPS control systems. This multi-functionality reduces the need for separate dedicated reconnection devices, managing overall system complexity while achieving reliable automated reconnection through the relay's versatile role in power management.
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
Automated reconnection of battery packs reduces errors, prevents deep discharge, and extends the runtime of UPS systems by ensuring batteries are reconnected only when the DC bus is charged to a suitable level, thereby minimizing damage to the UPS system.
Implementation Method 1
the power relay mechanism includes a motor actuator coupled to the control circuitry, the motor actuator being responsive to the first control signal to change the power relay mechanism from the open position to the closed position
Data Source
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AI summary
An uninterruptible power supply system (50) includes power converter circuitry (52) configured to convert AC input power to a first DC power and a second DC power to the first DC power, a battery pack (56) configured to provide the second DC power, a power relay mechanism (54) coupled to the power converter circuitry (52) and to the battery pack (56) that selectively moves between an open position and a closed position, the power relay mechanism (54) coupling the battery(56) pack to the power converter circuitry (52) when in the closed position and isolating the battery pack (56) from the power converter circuitry (52) when in the open position, and control circuitry (62) configured to provide a control signal, where the power relay mechanism (54) includes a motor actuator(60) coupled to the control circuitry (62), the motor actuator (60) being responsive to the control signal to change the power relay mechanism (54) from the open position to the closed position.