Power stealing system with an electric load

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Solution Overview

Problem

Existing evaporative cooling systems require additional wiring for electronic control, leading to increased heat dissipation and installation costs, and lack a thermostat specifically designed for four-wire systems.

Innovation Solution

A power stealing system that utilizes class X2 rated capacitors in series with each winding of a two-speed motor, along with full-wave rectifiers and linear regulators, to provide power for the control logic without additional wiring, allowing for efficient energy harvesting and reduced heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additional wiring is installed for electronic control, then control functionality is improved, but installation cost and heat dissipation increase

Engineering Contradiction:

Improvecontrol functionalityVSAvoidheat dissipation

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The system harvests power from the existing motor windings to self-power the control electronics, eliminating the need for additional wiring and reducing installation costs while maintaining control functionality

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The existing motor windings serve dual purposes: driving the motor and powering the control electronics through power harvesting, eliminating the need for separate power wiring

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If additional wiring is installed for electronic control, then control functionality is improved, but installation cost increases

Engineering Contradiction:

Improvecontrol functionalityVSAvoidinstallation cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The control system powers itself from the motor windings, eliminating the need for additional wiring infrastructure and reducing installation complexity and cost

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The power harvesting circuit merges the motor winding function with the control power supply function, eliminating the need for separate control wiring

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If power is harvested from motor windings, then additional wiring is eliminated, but power availability for control is reduced

Engineering Contradiction:

Improvewiring complexityVSAvoidpower availability

Core Design Contradiction:

Device complexityVSUse of energy by moving object

Solution Approach 1:

The system harvests only a small portion (less than 1%) of the total power from the motor windings, sufficient to power the control electronics without significantly impacting motor performance

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The capacitive reactance is carefully selected to limit the harvested current to less than 1% of the motor winding current, ensuring adequate power availability for control while minimizing impact on motor operation

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If capacitive elements are used for power harvesting, then additional wiring is eliminated, but power loss increases

Engineering Contradiction:

Improvewiring complexityVSAvoidpower loss

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The capacitive reactance is optimized to limit power loss to less than 1% of the total power, achieving power harvesting with minimal energy loss

Inventive Principle:

Principle #35Parameter changes

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

Enables the energization of evaporative cooling systems using existing four-wire installations without extra wiring, reducing heat dissipation and installation costs, while providing a new thermostat option with an initial efficiency advantage (EAV of 15K).

Implementation Method 1

a capacitive element having an input connected to the electrical load. Some power from the electrical load may go through the capacitive element to an input of a rectifier

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

A voltage regulator may have an input connected to an output of the rectifier to set and control a voltage level of the electrical power from the rectifier

Methodology Applied

Scientific EffectRectification: Diode

Data Source

PatentUS10910963B2Power stealing system with an electric load

Publication Date: 2021.02.02 RESIDEO LLC

AI summary

A power stealing system having an electrical load, a capacitive element having an input connected to the electrical load. Some power from the electrical load may go through the capacitive element to an input of a rectifier. A voltage regulator may have an input connected to an output of the rectifier to set and control a voltage level of the electrical power from the rectifier, and provide an output of power stolen from the electrical load. An amount of power flowing through the capacitive element may be less than one percent of power flowing through the electrical load.