Whirlpool Bath Load Controller for Single-Circuit Power Management
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Solution Overview
Problem
Conventional whirlpool bath installations require multiple high power circuits due to the electrical power demands of components like heaters, pumps, and blowers, necessitating separate circuit outlets and breakers, which complicates installation and management.
Innovation Solution
A control system with a single high voltage input power plug and a microprocessor-based controller that manages the on/off status of high power loads and low voltage loads to prevent exceeding the available current, eliminating the need for internal over-limit power protections and allowing simultaneous operation within the capacity of a single 20A circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate high power circuits are installed for heater, pump, and blower, then each load can operate independently with sufficient power, but the installation complexity and electrical infrastructure requirements increase
Solution Approach 1:
The patent combines multiple high power loads (heater, pump, blower) onto a single 20A circuit through intelligent load management. The controller monitors power consumption of each load and coordinates their operation to ensure total demand never exceeds 20A, eliminating the need for multiple separate circuits while maintaining operational reliability.
Solution Approach 2:
The system dynamically adjusts load operation based on real-time power consumption monitoring. The controller can selectively enable or disable specific loads depending on current circuit conditions, allowing flexible power distribution that adapts to varying operational requirements while staying within the 20A limit.
2Device complexity
If a single 20A circuit is used for all high power loads, then installation is simplified, but the total power available is limited
Solution Approach 1:
The controller implements dynamic load management that monitors and adjusts power distribution to each component in real-time. This allows the system to maximize utilization of the 20A circuit by selectively powering loads based on current demand and circuit capacity, effectively extracting maximum useful power from the limited circuit.
Solution Approach 2:
The system employs periodic monitoring and control cycles to manage load operation. By continuously cycling through load assessment and adjustment, the controller ensures optimal power distribution across different operational phases, allowing high power loads to operate sequentially or simultaneously within available capacity.
3Adaptability or versatility
If high power loads operate simultaneously without coordination, then all features are available, but the current limit is exceeded causing breaker trips
Solution Approach 1:
The controller implements feedback control by continuously monitoring the power consumption of each load and comparing it against the 20A circuit limit. When the combined demand approaches the threshold, the system automatically adjusts load operation to prevent overload, ensuring continuous reliable operation without breaker trips while maintaining maximum feature availability.
Solution Approach 2:
The system performs preliminary assessment of load power requirements before enabling operation. By pre-calculating and managing the power budget for each load, the controller prevents current limit violations before they occur, allowing versatile feature combinations to operate reliably within the 20A constraint.
Data Source
AI summary
A control system for a whirlpool bath installation, including a single input source wiring for connecting to an input source of high voltage AC electrical power having a nominal current rating. A plurality of high voltage output connections are connected to the input source through a corresponding plurality of switches, for power connections to a respective high voltage load devices, whose cumulative nominal current draw ratings exceeds the current rating of the input source. An electronic controller controls states of the switches in response to user input commands. The electronic controller implements an algorithm or a set of rules preventing a system utilization of the high voltage loads from exceeding a total current draw exceeding said nominal maximum current rating.