Solenoid Condensate Pump Control and Mounting for Low Noise
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Solution Overview
Problem
Conventional solenoid pumps connected to AC current sources through a single diode operate inefficiently and noisily due to unnecessary heat buildup and mechanical harmonics, limiting their voltage and frequency range.
Innovation Solution
A solenoid pump with an electronic control module that cuts off current to the electromagnetic solenoid coil once the plunger reaches its endpoint, combined with a mounting system for noise isolation, allowing operation over a wider AC voltage and frequency range (100-250 volts at 50/60 Hz) and reducing audible noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single diode is used to rectify AC current for the solenoid coil, then the pump can operate with simplified circuitry, but unnecessary heat buildup occurs in the coil after the plunger reaches its endpoint
Solution Approach 1:
The patent applies dynamics by making the circuit configuration changeable during operation. The full-wave rectified waveform dynamically switches between different conduction states of the two diodes based on the AC cycle phase, allowing the circuit to adapt its behavior to prevent heat buildup while maintaining simplicity.
Solution Approach 2:
The patent uses periodic action through the alternating current waveform, where each half-cycle activates different diode configurations. During one half-cycle, one diode conducts while the other is reverse-biased, and this periodically switches, creating the full-wave rectified waveform that prevents continuous heat buildup in the solenoid coil.
2Productivity
If full AC current is applied to the solenoid coil during intake portions, then the plunger is driven effectively toward the inlet, but the plunger slams into the end of the pump cylinder causing noise
Solution Approach 1:
The patent applies beforehand cushioning by using the reverse-biased diode to provide a gradual current decay path as the plunger approaches its endpoint. This gradual reduction of electromagnetic force cushions the plunger's arrival at the endpoint, preventing the slamming impact that causes noise while maintaining effective drive during the main intake portion.
3Ease of manufacture
If the solenoid pump is mounted directly to the support member, then installation is simple, but mechanical harmonics and noise are transmitted to the support structure
Solution Approach 1:
The patent introduces an intermediary element (mounting bracket or isolation material) between the solenoid pump and the support member. This intermediary absorbs and isolates mechanical harmonics and vibrations, preventing noise transmission to the support structure while maintaining installation simplicity through the bracket design.
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 solution enhances energy efficiency and reduces noise levels, enabling the solenoid pump to operate effectively across a broader range of AC current sources without straining the solenoid coil or plunger, while minimizing vibrations and noise.
Implementation Method 1
the electromagnetic solenoid coil 22 is energized, and the plunger 10 is driven by the electromagnetic solenoid coil 22 toward the inlet 6
Implementation Method 2
the plunger 10 is driven by the plunger spring 20 toward the outlet 8
Implementation Method 3
The voltage from the source of AC current is shown as a full waveform 24 in FIG. 2. The voltage applied to the electromagnetic solenoid coil 22, as a result of the operation of the diode, is shown as a half wave rectified waveform 26 in FIG. 2
Data Source
AI summary
A condensate pump for an HVAC system includes a reservoir, a solenoid pump assembly with a solenoid pump, and a solenoid pump electronic control module for limiting the amount of energy delivered to the solenoid pump during one half cycle from an AC current source. The solenoid pump is mounted in the solenoid pump assembly by means of shock absorbing material, and the solenoid pump assembly is mounted on a support member with shock absorbing material interposed between the solenoid pump assembly and the support member.