Tapped Resistor Load Bank Circuit for Fine Discrete Load Steps
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Solution Overview
Problem
Existing load bank systems fail to provide a large number of discrete loading steps without constraints on resistor power ratings, leading to potential engine damage and inefficiencies in testing generators and power sources.
Innovation Solution
A load bank system circuit topology using at least five switches and five resistors, including a special tap resistor that can be divided into parts, to generate a large number of discrete loading steps with identical or multi-value resistors, minimizing duplicate and high power difference steps, and achieving a high maximum to minimum load ratio and lowest value average resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a load bank system uses a limited number of resistors and switches, then the device complexity is reduced, but the number of discrete loading steps is insufficient
Solution Approach 1:
The resistor R3 is divided into multiple segments using taps (R3A, R3B, R3C) along its length. These segments can be independently connected to different switch combinations, allowing the same physical resistor to provide multiple discrete resistance values. This segmentation enables the system to generate more loading steps without adding more resistors or switches to the circuit.
Solution Approach 2:
The patent introduces a spatial dimension to the resistor configuration by placing taps at different positions along the length of resistor R3. This transforms a one-dimensional resistor into a multi-tap structure that can be accessed from multiple switch combinations, effectively increasing the dimensionality of the switching network and enabling more discrete loading steps from the same component count.
2Measurement precision
If the load bank generates a large number of discrete loading steps, then the measurement precision of power source testing is improved, but the device complexity increases
Solution Approach 1:
The resistor R3 serves multiple functions simultaneously: it provides a base resistance value, gets divided into segments for fine adjustment, and can be combined with other resistors (R1, R2, R4, R5) in series or parallel configurations. This multi-functionality allows a single resistor with taps to replace what would otherwise require multiple separate resistors, achieving high measurement precision without proportionally increasing device complexity.
Solution Approach 2:
The circuit configuration is made dynamic through the switching network that can connect different segments of R3 to different terminals based on the desired loading step. The taps on R3 enable dynamic reconfiguration of the resistance values without physically changing components, allowing the system to adapt between different loading steps efficiently.
3Ease of manufacture
If identical value resistors are used in the load bank, then the ease of manufacture is improved, but the adaptability to generate varied loading steps is limited
Solution Approach 1:
By segmenting resistor R3 into multiple taps, the patent enables a single identical-value resistor to provide multiple effective resistance values when combined with other identical resistors in different switch configurations. This segmentation allows the system to achieve high adaptability in generating varied loading steps while maintaining the simplicity of using only identical-value resistors throughout the circuit.
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 system enables efficient and accurate testing of generators by generating a high number of discrete loading steps with minimal duplicate and high power difference steps, ensuring engine safety and precise load simulation.
Implementation Method 1
A Load Bank is a device which develops an electrical load, applies the load to an electrical power source and converts or dissipates the resultant power output of the source. Load banks are mainly resistive networks used to dissipate the electrical energy.
Data Source
AI summary
The present invention relates generally to Load Banks for testing generators and electric power sources and more particularly the present invention discloses a load bank system circuit topology and method thereof, to generate large number of discrete loading steps. The system and method thereof employs at least five switches RL1, RL2, RL3, RL4, RL5, at least five resistors R1, R2, R3, R4, R5, the R3 a special tap resistor having at least one tap movable along the length of the resistor R3 and divide the resistor into parts, at least two terminals, terminal T5, terminal T6 for connecting the load bank to a power source under test, to generate a large number of loading steps having minimum number of duplicate loading steps, minimum number of high power difference loading steps, high maximum to minimum load ratio and lowest value average resolution of the loading step.