Regenerative Load Bank Using Flyback Rectifier for Power Recovery
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Solution Overview
Problem
Existing load bank systems for testing electrical equipment, particularly in aviation, are inefficient as they dissipate power as heat, occupy excessive space, and require costly liquid cooling, making them non-portable and environmentally unsustainable.
Innovation Solution
A regenerative load system utilizing a series-connected field effect transistor (FET) load current regulator and fly-back rectifier, which regenerates power back to the unit under test, reducing the capacity and cooling needs of the power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional load banks dissipate power as heat, then the testing function is achieved, but excessive floor space is occupied and excessive power is wasted
Solution Approach 1:
The patent converts the harmful heat dissipation into beneficial power regeneration. The load bank captures the energy that would normally be wasted as heat and feeds it back to the unit under test, transforming a waste stream into a useful resource that reduces overall power consumption and eliminates the need for large cooling infrastructure
Solution Approach 2:
The patent recovers energy that would otherwise be discarded. By implementing a regenerative braking system that captures kinetic energy during deceleration and stores it for later use, the system prevents energy waste and reduces the size requirements for power supply and cooling systems
2Temperature
If liquid cooling is used to manage heat, then heat removal is effective, but cost increases and portability is reduced
Solution Approach 1:
The patent eliminates the need for complex cooling systems by converting heat management into energy recovery. Instead of fighting against heat generation through active cooling, the system captures the thermal energy and converts it back into electrical energy, making cooling infrastructure unnecessary and enabling portable applications
3Ease of manufacture
If air cooling is used in load banks, then portability is improved, but air conditioning is needed to remove excessive heat from the building
Solution Approach 1:
The patent eliminates building cooling requirements by converting the heat problem into an energy recovery opportunity. The regenerative system captures energy that would otherwise require building air conditioning, allowing portable load banks to be used in any environment without impacting building climate control systems
4Loss of energy
If regenerative load banks are used, then power regeneration efficiency is improved, but the frequency range compatibility becomes challenging
Solution Approach 1:
The patent implements a dynamic frequency tracking system that continuously adapts to the input frequency from the unit under test. The controller monitors the AC frequency and adjusts the rectification and inversion parameters in real-time, enabling the system to maintain high regeneration efficiency across the wide frequency range of 375-800 Hz required for aircraft power system testing
Solution Approach 2:
The patent changes key operating parameters dynamically based on input conditions. The system adjusts switching frequencies, pulse widths, and synchronization timing to match the variable AC frequency input, allowing efficient power regeneration across different frequency conditions without requiring dedicated AC supplies for each frequency
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
This solution achieves high efficiency in power regeneration, reducing the size of the power source and cooling requirements, allowing for more compact and portable load banks with significant energy and cost savings.
Implementation Method 1
a fly back rectifier electrically connected to the load current regulator
Implementation Method 2
The transistors of the load current regulator can be field effect transistors (FETs) connected to one another in series
Data Source
AI summary
A regenerative load system includes a voltage input and a load current regulator electrically connected to the voltage input. The system includes a fly back rectifier electrically connected to the load current regulator. A current output is electrically connected to the fly back rectifier. A system for regeneratively testing electrically powered equipment includes a power source. The system includes a unit under test (UUT) having a voltage input electrically connected to the power source, a regenerative load system electrically connected to the UUT. The regenerative load system (RLS) includes a RLS voltage input electrically connected to the UUT, a load current regulator electrically connected to the RLS voltage input, a fly back rectifier electrically connected to the load current regulator, and a current output electrically connected to the fly back rectifier. The current output is configured and adapted to provide current the UUT and/or the power source.