TRIAC Power Control Device with Relay Bypass

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Solution Overview

Problem

Phase control circuits with TRIAC elements face destruction due to mechanical switch bouncing, which causes high current density and voltage rise issues when switching from power-limited to full-load modes, leading to potential TRIAC damage.

Innovation Solution

A switching device is used to activate a parallel conduction path while disconnecting the TRIAC from mains voltage, and a relay with a break contact and make contact is employed to ensure safe switching, with voltage detection for zero crossing activation to minimize induction voltage impact on the TRIAC.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a mechanical switch is used to bypass the TRIAC for full power operation, then power loss is reduced and cooling requirements are minimized, but the mechanical switch bouncing causes high current density and voltage rise that destroys the TRIAC

Engineering Contradiction:
Improvepower lossVSAvoidTRIAC durability
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The patent applies preliminary action by disconnecting the TRIAC from the mains voltage before activating the mechanical switch for full power operation. The control circuit detects when full power is required and opens the TRIAC circuit first, then closes the mechanical switch. This sequence ensures the TRIAC is not present in the circuit when the mechanical switch bounces, preventing the bouncing-induced high current density from destroying the TRIAC while still achieving low power loss through the mechanical switch bypass

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If the TRIAC carries full motor current for power control, then power control functionality is achieved, but power dissipation in the TRIAC requires cooling measures

Engineering Contradiction:
Improvepower control functionalityVSAvoidTRIAC temperature
Core Design Contradiction:
Ease of operationVSTemperature

Solution Approach 1:

The patent applies dynamics by dynamically switching between two operational modes: phase control mode where the TRIAC regulates power to the motor, and full power mode where a mechanical switch bypasses the TRIAC. The control circuit monitors the power control setting and automatically transitions between modes, keeping the TRIAC out of the circuit when full power is required. This dynamic switching eliminates continuous power dissipation in the TRIAC while maintaining full power control functionality when needed

Inventive Principle:
Principle #15Dynamics

3Device complexity

If the TRIAC remains connected during mechanical switch activation, then switching simplicity is maintained, but the TRIAC is exposed to bouncing-induced voltage rises and current density that cause destruction

Engineering Contradiction:
Improveswitching circuit complexityVSAvoidTRIAC protection
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent applies preliminary action by implementing a controlled switching sequence where the TRIAC is disconnected from the mains voltage before the mechanical switch is activated. The control circuit generates control signals that first open the TRIAC circuit, wait for a brief period to ensure complete disconnection, then close the mechanical switch. This preliminary disconnection action protects the TRIAC from the harmful effects of mechanical switch bouncing while maintaining relatively simple circuit architecture through the use of a control circuit that coordinates the switching sequence

Inventive Principle:
Principle #10Preliminary action

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 solution prevents TRIAC destruction by ensuring no current flows through the TRIAC during bouncing, reducing power loss and heat generation, and allowing safe switching between modes without damaging the TRIAC.

Implementation Method 1

a phase control circuit with a TRIAC element and a control circuit for driving the TRIAC element, the TRIAC element having a control terminal, a first main terminal connected to a consumer connection point and a second main terminal connected to a supply voltage connection point

Methodology Applied
Scientific EffectTRIAC switching:

Implementation Method 2

the switching device has a mechanical switching element, in particular a relay with a break contact and a make contact

Methodology Applied
Scientific EffectElectromagnetic actuation: Electromagnet

Implementation Method 3

a voltage detection device is provided, which detects the voltage present at the consumer connection point. More preferably, the voltage detection device detects a zero crossing of the voltage

Methodology Applied
Scientific EffectVoltage detection:

Data Source

PatentEP2648331B1Power control device and method for power control
Publication Date: 2018.10.31 KURZ ELEKTRONIK GMBH
  • EP2648331B1 patent drawingFigure 1~2
  • EP2648331B1 patent drawingFigure 3

AI summary

The device (10) has a triac element (12) that is provided with a gate terminal, and two direct lines (18,20) that are respectively connected with a load terminal (22) and a supply voltage terminal (24). Controllable switching units (30,32,38) are arranged to provide an electrical connection between an input terminal (40) and two output terminals (42,44). The output terminals are connected with direct lines, such that a conductive path (34) is formed between direct line (18) and output terminal (42) while a conduction path (36) is formed direct line (18) and triac element. An independent claim is included for a method for controlling power of electrical load.