Regenerative DC Load Feedback Control for Energy Recovery
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Solution Overview
Problem
Existing load banks used for testing power distribution products waste significant energy as heat, requiring large power sources and increasing cooling demands, as they dissipate power without regenerating any back to the system.
Innovation Solution
A regenerative DC load system that includes an input circuit, output circuit, low pass filter circuit, current regulating circuit, and link voltage regulating circuit, which senses and adjusts current and voltage to regenerate a portion of the power back to the power distribution device, allowing for efficient power utilization and reduced cooling needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional load bank is used to test power distribution devices, then the load characteristics can be simulated, but significant energy is wasted as heat requiring large power sources and increasing cooling demands
Solution Approach 1:
The patent implements feedback control by sensing the current through a current sense resistor and using operational amplifiers to regulate the switching of power transistors. The control circuit continuously monitors the current flow and adjusts the switching duty cycle to maintain desired current levels while enabling regenerative operation, where energy returned to the source is fed back into the system for reuse
Solution Approach 2:
The patent changes the operational parameters of the load bank from purely dissipative to regenerative by controlling the switching frequency and duty cycle of the power transistors. By adjusting these parameters, the system can operate in different modes including regenerative mode where energy is returned to the source, thereby reducing the required power source capacity and minimizing energy waste
2Loss of energy
If a traditional load bank dissipates power as heat, then load simulation is achieved, but cooling requirements and energy loss increase substantially
Solution Approach 1:
The patent converts the harmful effect of energy dissipation into a beneficial regenerative process. Instead of allowing energy to be wasted as heat in resistive loads, the system uses controlled switching of power transistors to return energy to the power source. The heat that would have been generated is instead used to charge energy storage elements that feed back into the system, transforming energy loss into useful energy recovery
Solution Approach 2:
The patent changes the thermal parameter profile by eliminating the purely resistive heating path. Through controlled switching operation, the system minimizes I²R losses and instead channels energy through regenerative paths, dramatically reducing heat generation while maintaining the same load simulation capability
3Power
If large power sources are used to compensate for energy waste, then sufficient power capacity is available, but system complexity and cost increase
Solution Approach 1:
The patent implements self-service operation where the load bank system manages its own energy requirements through regenerative operation. The system recovers energy during load transitions and feeds it back to the power source, making the system self-sufficient in managing energy demands. This eliminates the need for oversized power sources and reduces reliance on external energy infrastructure
Solution Approach 2:
The patent creates a multi-functional system that can operate in multiple modes: dissipative load mode, regenerative mode, and energy storage mode. The same circuit topology and power transistors can switch between these modes based on operational requirements, providing universal functionality that replaces what would otherwise require separate systems
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 regenerative DC load system enables power distribution devices to be tested without wasting energy, using smaller power supplies and reducing heat generation and cooling requirements, thereby improving energy efficiency and test system performance.
Implementation Method 1
A regenerative DC load system that includes an input circuit, output circuit, low pass filter circuit, current regulating circuit, and link voltage regulating circuit, which senses and adjusts current and voltage to regenerate a portion of the power back to the power distribution device
Data Source
AI summary
A regenerative direct current (DC) load includes an input circuit, an output circuit, a low pass filter circuit, and a current regulating circuit. The input circuit is configured to receive electrical power. The output circuit is configured to provide electrical power. The low pass filter circuit is electrically coupled to the output in series. The current regulating circuit is configured to regulate a current of the electrical power. The current regulating circuit is electrically coupled to the input. The current regulating circuit includes a first switch, and a first control circuit. The first switch is electrically coupled between the input circuit and ground. The first control circuit is configured to sense the current and adjust a cycle duration and/or duty cycle of the first switch based upon the sensed current.