Resistor Grid Braking Capacity Control by Element Temperature
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Solution Overview
Problem
The capacity of resistor grids in resistive braking systems is limited by maximum allowable temperatures, ambient conditions, and altitude, leading to potential failure or underutilization, necessitating improved designs and control systems to enhance longevity and braking capacity under varied conditions.
Innovation Solution
A resistor grid system with temperature sensors and a control circuit that determines resistive braking capacity based on resistor element temperatures, ambient conditions, and power capacity differentials, accompanied by a graphical display to indicate available braking capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the resistor grid operates at maximum power capacity, then braking performance is improved, but the temperature of resistor elements exceeds maximum allowable limits leading to component failure
Solution Approach 1:
The system dynamically adjusts the resistive braking capacity based on real-time temperature measurements from multiple sensors. The control system continuously monitors resistor element temperatures and modifies the braking capacity to maintain operation within safe temperature limits while maximizing braking performance when conditions permit
Solution Approach 2:
The system changes the operating parameters of the resistor grid by adjusting the resistive braking capacity as a function of temperature. By varying this parameter based on thermal conditions, the system optimizes the balance between braking performance and component longevity
2Power
If the resistor grid is designed for high power capacity, then braking performance is improved, but the system becomes vulnerable to failure under varying ambient conditions and altitude
Solution Approach 1:
The system incorporates multiple temperature sensors that provide continuous feedback on resistor element temperatures. This feedback loop enables the control system to adjust the resistive braking capacity in real-time, ensuring reliable operation across varying ambient conditions and altitude by preventing thermal overload
Solution Approach 2:
The system performs preliminary thermal management by continuously monitoring temperatures and adjusting braking capacity before critical thermal conditions develop. This proactive approach prevents component failure and ensures reliable operation under varying environmental conditions
3Productivity
If temperature monitoring and control systems are added to the resistor grid, then braking capacity optimization is improved, but the device complexity increases
Solution Approach 1:
The control system automatically manages the resistive braking capacity based on temperature sensor inputs without requiring external intervention. The system self-adjusts to optimize braking performance while maintaining thermal safety, reducing the need for complex external control mechanisms
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
Enhances the resistive braking capacity by utilizing additional power capacity when resistor elements are below maximum operating temperature, reducing friction brake wear and optimizing system performance across varying conditions.
Implementation Method 1
a temperature sensor positioned to measure a temperature of at least one of the plurality of resistor elements
Implementation Method 2
a plurality of resistor elements to dissipate the generated electric power as heat
Data Source
AI summary
Provided herein is a system including a resistor grid comprising a plurality of resistor elements, the resistor grid electrically coupled to a motor of an electric drive machine; a temperature sensor arranged to measure a temperature of at least one of the plurality of resistor elements; a control circuit comprising one or more processors and memory structured to store instructions that, when executed by the one or more processors, cause the control circuit to: determine a temperature of the least one resistor element, according to measurements from the temperature sensor; and determine a resistive braking capacity of the resistor grid within a power capacity differential, according to the determined temperature of the resistor element; and a display configured to render a graphical representation of the resistive braking capacity of the resistor grid relative to the power capacity differential.