Rectifier Phase Switching for Low-Load Robot Actuator Power
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Solution Overview
Problem
Existing rectifier devices in industrial robots consume excessive energy due to handling three phases of AC power regardless of load demand, leading to high energy consumption during low-load operations.
Innovation Solution
A method of controlling the rectifier device in a power system to selectively handle fewer phases of AC power during low-load conditions, including a first power mode for high-load operations and a second power mode for low-load operations, reducing energy consumption by alternating phases and utilizing an energy storage during minimal power needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the rectifier device handles three phases of AC power continuously, then the power supply capability is sufficient for high-load operations, but energy consumption increases during low-load operations
Solution Approach 1:
The rectifier device dynamically switches between handling three phases of AC power and handling only one phase, adapting its operational state to the current load demand. This dynamic adjustment allows the system to maintain sufficient power supply capability during high-load operations while reducing energy consumption during low-load operations, directly resolving the technical contradiction between power supply capability and energy consumption.
Solution Approach 2:
The system changes the operational parameter of the rectifier device by altering the number of AC phases it handles (from three phases to one phase). This parameter change enables the rectifier to adjust its power processing capacity to match the actual load requirements, thereby reducing unnecessary energy consumption during low-load conditions while maintaining adequate power supply capability.
2Reliability
If the rectifier device handles three phases of AC power, then power factor correction is maintained, but energy consumption increases due to continuous switch control
Solution Approach 1:
Instead of continuously performing full three-phase rectification with power factor correction, the system applies partial action by handling only one phase of AC power during low-load conditions. This partial operation reduces the energy consumption associated with continuous switch control while still providing sufficient power supply for low-load operations, resolving the contradiction between maintaining power factor correction and reducing energy consumption.
3Power
If the rectifier device operates in high-power mode continuously, then sufficient power is provided for all operational states, but energy waste occurs during low-speed operations, standstill, or motor shutdown
Solution Approach 1:
The rectifier device dynamically adjusts its operational mode based on the robot's operational state. During high-speed operations, it handles three phases of AC power to provide sufficient power. During low-speed operations, standstill, or when motors are turned off, it switches to handling only one phase, thereby eliminating energy waste while ensuring sufficient power provision is maintained when needed.
Solution Approach 2:
The system extracts and removes the unnecessary two-phase power handling capability during low-load conditions, retaining only the essential one-phase operation. This extraction of excess capacity eliminates energy waste during low-speed operations, standstill, and motor shutdown while maintaining sufficient power provision for actual operational needs.
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
Reduces energy consumption by up to 20% during low-load operations by selectively controlling the rectifier device to handle fewer phases, optimizing power usage based on load demand and extending the rectifier's lifespan.
Implementation Method 1
a rectifier device arranged to convert input alternating current, AC, power from a power source to direct current, DC, power
Data Source
AI summary
A method of controlling power supply to an electric actuator using a power system comprising a rectifier device arranged to convert input AC power from a power source to DC power, includes controlling the rectifier device in a first power mode where the rectifier device handles a plurality of phases of the input AC power or a plurality of phases derived from the input AC power; and controlling the rectifier device in a second power mode where the rectifier device handles at least one phase and fewer phases than in the first power mode.