Thermal Valve Voltage Control for Lower Rush Current
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermal valves in heat pump-type floor heating devices require substantial rush current for valve opening due to the use of PTC heaters, necessitating large-capacity electrical components and noise mitigation measures.
Innovation Solution
A method for controlling the thermal valve by applying a lower voltage initially and gradually increasing it to the operating voltage, with the option to reduce voltage once fully open, allowing for reduced peak current and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PTC heater is used to open the thermal valve, then the valve opening action is achieved, but substantial rush current is required
Solution Approach 1:
A preliminary action is performed by applying a first voltage lower than the operating voltage before applying the full operating voltage. This preliminary voltage application prepares the PTC heater by gradually heating it, preventing the substantial rush current that would occur if full voltage were applied directly. The controller executes this preliminary action as a first step in the valve opening process.
Solution Approach 2:
The system transitions from a static voltage application approach to a dynamic one by continuously variable voltage control. The controller adjusts the voltage applied to the PTC heater in real-time, starting with a lower first voltage and progressively increasing it to the operating voltage. This dynamic control optimizes the heating process and minimizes rush current while ensuring reliable valve opening.
2Reliability
If substantial rush current is applied to open the valve, then the valve opens reliably, but large-capacity electrical components are required
Solution Approach 1:
The preliminary action of applying a reduced first voltage before full operating voltage eliminates the need for large-capacity electrical components. By gradually heating the PTC heater with lower initial voltage, the system avoids the substantial rush current that would require oversized electrical components, thereby simplifying the overall device configuration.
Solution Approach 2:
The controller changes the voltage parameter dynamically during the valve opening process. Instead of maintaining a constant high voltage that would require large electrical components, the system varies the voltage from a first lower voltage to the operating voltage, optimizing component sizing while maintaining reliable operation.
3Speed
If full operating voltage is applied immediately, then the valve opens quickly, but noise mitigation measures are required
Solution Approach 1:
The preliminary action of applying a first voltage lower than the operating voltage reduces electrical noise during the valve opening process. This gradual voltage application minimizes electromagnetic interference and noise generation while still achieving timely valve opening through the controlled progression to full operating voltage.
Solution Approach 2:
The valve opening process is divided into periodic stages: first applying a lower first voltage for an initial period, then transitioning to the full operating voltage. This periodic action pattern controls noise generation by avoiding sudden full-power application while maintaining overall opening speed through structured voltage progression.
4Reliability
If continuous high voltage is applied to keep the valve open, then the valve remains reliably open, but power consumption increases
Solution Approach 1:
After the valve reaches its fully open state, the system discards the high operating voltage and recovers energy by applying a reduced second voltage. This allows the valve to remain reliably open while significantly reducing power consumption, as the PTC heater only needs minimal power to maintain the valve in the open position rather than continuously heating it.
Solution Approach 2:
The voltage applied to the thermal valve is dynamically adjusted based on its operational state. The system transitions from high operating voltage during opening to a lower second voltage during the maintained open state, optimizing both reliability and energy efficiency through continuous voltage adaptation.
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 reduces the need for large-capacity electrical components, simplifies noise mitigation, and conserves power while maintaining reliable operation and valve functionality.
Implementation Method 1
power is supplied to the electrical heater 16, causing the wax to expand
Implementation Method 2
causing the wax to expand, and the bellows 15 thereby expands
Data Source
AI summary
The invention provides a method for controlling a thermal valve which eliminates need for substantial rush current as in the past and can be inexpensively configured and more reliably operated. The method for controlling the thermal valve 10 opened by application of a designated operating voltage Vr, wherein a voltage Va that is lower than the operating voltage Vr is initially applied for a designated time t as the applied voltage, thereby lowering the rush current. The applied voltage is then increased to the operating voltage Vr to open the thermal valve 10. Then, after a designated time T has passed, a voltage Vb that is lower than the operating voltage Vr is continuously applied to the thermal valve 10 to conserve consumption power.