Shaping Machine Power Supply with Dual-Range Regulation
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Solution Overview
Problem
Current power supply systems for shaping machines, such as injection moulding machines, face issues of large apparatus size, high losses, high costs, poor capacity utilization, high peak powers, and high reactive power demand due to the need for large output stages to handle peak power ratios up to 4:1, leading to inefficient energy management and increased operational expenses.
Innovation Solution
Implementing a closed-loop regulating system that defines two voltage or current ranges, with the second range being smaller and contained within the first, to adjust mains power supply accordingly, allowing for reduced peak power handling through an integrated electrical power storage device, thereby optimizing system capacity utilization and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large output stages are designed to handle peak power ratios up to 4:1, then the system can meet maximum power demands, but the apparatus size increases and capacity utilization deteriorates
Solution Approach 1:
The patent segments the power supply system into two distinct ranges: a first range for nominal power operation and a second range for peak power operation. By dividing the power delivery function across different operational modes, the system avoids the need for oversized output stages designed for continuous peak power, thereby reducing apparatus size while maintaining peak power capability when needed.
Solution Approach 2:
The patent implements dynamic switching between two operational ranges based on real-time power demands. The system transitions from a first operational range to a second operational range when peak power is required, and vice versa. This dynamic adaptation allows the output stages to be optimized for nominal power while temporarily handling peak power through controlled switching, eliminating the need for permanently oversized components.
2Power
If oversized power storage devices are used to handle peak power demands, then peak power requirements are met, but costs increase and capacity utilization decreases
Solution Approach 1:
The patent applies partial action by providing power storage capacity that is sufficient for the second (peak) operational range rather than designing for continuous maximum power. The power storage device is sized to handle peak demands temporarily rather than continuously, reducing manufacturing costs while still meeting peak power requirements when they occur.
Solution Approach 2:
The patent changes the operational parameters of the power supply system by defining two distinct ranges with different power levels. The system operates in a first range for normal conditions and switches to a second range for peak demands. This parameter change allows the power storage device to be optimized for the specific peak power duration and magnitude rather than continuous maximum output, reducing overall system cost.
3Power
If the system operates with high peak power ratios, then maximum power demand is satisfied, but losses increase and energy efficiency deteriorates
Solution Approach 1:
The patent implements periodic switching between operational ranges based on actual power demands. Instead of continuously operating at high power levels, the system periodically transitions between the first and second ranges according to the shaping machine's actual needs. This periodic action reduces energy losses by keeping the system in the more efficient first range during normal operation while still providing peak power capability when required.
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 approach enables the use of smaller, more cost-effective power supply systems with improved capacity utilization, reducing the need for oversized power storage devices and minimizing peak power demands from the mains network, while ensuring stable operation during peak power conditions.
Implementation Method 1
an integrated electrical power storage device (5) is provided
Data Source
AI summary
A power supply apparatus for a shaping machine includes an intermediate circuit to be connected to at least one drive of the shaping machine, a power supply mains, and a power storage device. A measuring device measures an electric voltage or an electric current at the intermediate circuit, and a closed-loop regulating device regulates a power transfer between the power supply mains and the intermediate circuit based on the measured voltage or the measured current. The closed-loop regulating device can increase a main power furnished by the power supply main to the intermediate circuit if the measured voltage or the measured current leaves a first range, and can reduce the main power if the measured voltage or the measured current passes into a second range, the second range being smaller than the first range and completely contained in the first range.