Line side power and energy management system and methods

• US 20020034086A1
• Filed: 06/01/2001
• Published: 03/21/2002
• Est. Priority Date: 06/01/2000
• Status: Active Grant

• Current Assignee: Powertek International Corporation
• Original Assignee: Powertek International Corporation
• Inventors: Scoggins, Robert L., Crompton, James O. Jr., Fulton, Michael A., Sheaffer, Anthony D.
• Granted Patent: US 6,486,641 B2
• Time in Patent Office: Days
• US Class Current: 363/39
• CPC Class Codes: H01F 29/00 Variable transformers or inductances not covered by group H01F21/00 tap change devices H01H9/0005
• CPC Class Codes: H02P 13/06 by tap-changing; by rearranging interconnections of windings

Abstract

Apparatus and methods for power regulation of electrical loads to provide reduction in power consumption by the electrical loads. The power regulation system is coupled to an AC power source outputting an input voltage between a first node and a second node. Included in the system is a first transformer having a winding having a first end and a second end, wherein the first end is electrically coupled to the first node and the second end is electrically coupled to the second node to receive the input voltage, and a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage. The system also has a second transformer that has a primary coil having a first end and a second end, wherein the first end is electrically coupled to the output node and the second end is electrically coupled to the second node to receive the control voltage from the first transformer, and a secondary coil having a first end and a second end, wherein the first end is electrically coupled to the first node. The system can be used in connection with a load having a first terminal and a second terminal can also be included in the system, wherein the first terminal is electrically connected to the second end of the second transformer and the second terminal is electrically coupled to the second node. The primary coil and secondary coil of the second transformer are electromagnetically coupled to each other and so arranged that when the control voltage from the first transformer is applied to the first end and the second end of the primary coil, an output voltage is generated between the first end and the second end of the secondary coil, wherein the output voltage is substantially 180° out of phase from the input voltage so as to generate an effective voltage applied to the load, and wherein the effective voltage is less than the input voltage and substantially equals to the difference between the input voltage and the output voltage, resulting a reduction in power consumption of the load.

Claims

1. A power regulation system coupled to an AC power source outputting an input voltage between a first node and a second node, comprising:

a. a first transformer, comprising;

i. a winding having a first end and a second end, wherein the first end is electrically coupled to the first node and the second end is electrically coupled to the second node to receive the input voltage; and

ii. a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage; and

b. a second transformer, comprising;

i. a primary coil having a first end and a second end, wherein the first end is electrically coupled to the output node and the second end is electrically coupled to the second node to receive the control voltage from the first transformer; and

ii. a secondary coil having a first end and a second end, wherein the first end is electrically coupled to the first node,

wherein the primary coil and secondary coil are electro-magnetically coupled to each other and so arranged that when the control voltage from the first transformer is applied to the first end and the second end of the primary coil, an output voltage is generated between the first end and the second end of the secondary coil;

wherein the output voltage is substantially 180°

out of phase from the input voltage so as to generate between the first end of the secondary coil and the second node an effective voltage that is less than the input voltage and substantially equals to the difference between the input voltage and the output voltage.

2. The system of claim 1, further comprising:

a. a driver engaging the movable wiper arm through the body of the movable wiper arm; and

d. a controller, in control communication with the driver, causing the driver to move the movable wiper arm to a selected position between the second end and the first end of the winding, so that a control voltage with a selected value is generated between the output node and the second end of the winding.

3. The system of claim 2, wherein the controller is programmable.

4. The system of claim 3, wherein the controller comprises a digital processor.

5. The system of claim 3, wherein the controller comprises an analog processor.

6. The system of claim 2, further comprising a user interface in communication with the controller.

7. The system of claim 6, wherein the user interface comprises a touchscreen having a plurality of settings, each setting including icons, each corresponding to a control signal that is communicated to the controller to cause the driver to move the movable wiper arm to a selected position, and displays, each displaying information associated with the operation of the system.

8. The system of claim 6, wherein the user interface is adapted to receive an input from a user and generate a control signal that is communicated to the controller to cause the driver to move the movable wiper arm to a selected position and to display to the user information associated with the operation of the system.

9. The system of claim 2, wherein the driver comprises a motor.

10. The system of claim 1, further comprising a load having a first terminal and a second terminal, wherein the first terminal is electrically coupled to the second end of the second transformer and the second terminal is electrically coupled to neutral to receive the effective voltage and generate a reduced power consumption.

11. The system of claim 1, wherein the first transformer is a variable autotransformer having a capacity of output voltage ranging from 0 volts to approximately 220% of the input voltage.

12. The system of claim 1, wherein the second transformer is a buck transformer.

13. The system of claim 12, wherein the primary coil and secondary coil of the buck transformer each has a polarity, and the polarity of the primary coil being reversed from the polarity of the secondary coil.

14. The system of claim 13, wherein the buck transformer is a torroidal transformer.

15. The system of claim 14, wherein the torroidal transformer has a ratio of 4:

1 (four to one) between the winding of the primary coil to the winding of the secondary coil.

17. The system of claim 16, further comprising, on each phase, at least one load having a first terminal and a second terminal, wherein the first terminal is electrically coupled to the second end of the second transformer on the phase and the second terminal is electrically coupled to neutral to receive the effective voltage and generate a reduced power consumption.

18. The system of claim 16, further comprising:

a. a driver engaging the movable wiper arm through the body of the movable wiper arm of the first transformer on the phase; and

b. a controller, in control communication with the driver, causing the driver to move the movable wiper arm to a selected position between the second end and the first end of the winding, so that a control voltage with a selected value is generated between the output node and the second end of the winding of the first transformer on the phase.

19. The system of claim 18, wherein the controller is in control communication with each driver.

20. The system of claim 19, wherein the controller is programmable.

21. The system of claim 20, wherein the controller comprises a digital processor.

22. The system of claim 20, wherein the controller comprises an analog processor.

23. The system of claim 16, further comprising a user interface in communication with the controller.

24. The system of claim 23, wherein the user interface comprises a touchscreen having a plurality of settings, each setting including icons, each corresponding to a control signal that is communicated to the controller to cause at least one driver to move a corresponding movable wiper arm to a selected position, and displays, each displaying information associated with the operation of the system.

25. The system of claim 23, wherein the user interface is adapted to receive an input from a user and generate a control signal that is communicated to the controller to cause at least one driver to move a corresponding movable wiper arm to a selected position and to display information associated with the operation of the system.

26. The system of claim 18, wherein the driver comprises a motor.

27. The system of claim 16, wherein the first transformer on each phase is a variable autotransformer having a capacity of output voltage ranging from 0 volts to approximately 220% of the input voltage.

28. The system of claim 16, wherein the second transformer on each phase is a buck transformer.

29. The system of claim 28, wherein the primary coil and secondary coil of the buck transformer each has a polarity, and the polarity of the primary coil being reversed from the polarity of the secondary coil.

30. The system of claim 28, wherein the buck transformer is a torroidal transformer.

31. The system of claim 30, wherein the torroidal transformer has a ratio of 4:

1 (four to one) for the winding of the primary coil to the winding of the secondary coil.

16. A power regulation system coupled to a three-phase AC power source, each phase outputting an input voltage related to neutral, respectively, comprising:

on each phase,

a. a first transformer, comprising;

i. a winding having a first end and a second end electrically coupled to the phase and neutral, respectively, to receive the input voltage from the phase; and

ii. a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage; and

b. a second transformer, comprising;

i. a primary coil having a first end and a second end, wherein the first end is electrically coupled to the output node and the second end is electrically coupled to neutral to receive the control voltage from the first transformer; and

ii. a secondary coil having a first end and a second end, wherein the first end is electrically coupled to the phase;

wherein the primary coil and secondary coil are electromagnetically coupled to each other and so arranged that when the control voltage from the first transformer is applied to the first end and the second end of the primary coil, an output voltage is generated between the first end and the second end of the secondary coil;

wherein the output voltage is substantially 180°

out of phase from the input voltage so as to generate between the first end of the secondary coil and neutral an effective voltage that is less than the input voltage and substantially equals to the difference between the input voltage and the output voltage.

32. A power regulation system coupled to a multi-phase AC power source, each phase providing an input voltage related to neutral, respectively, comprising:

on each phase,

a. a first transformer, comprising;

i. a winding having a first end and a second end electrically coupled to the phase and neutral, respectively, to receive the input voltage from the phase; and

ii. a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage; and

b. a second transformer, comprising;

i. a primary coil having a first end and a second end, wherein the first end is electrically coupled to the output node and the second end is electrically coupled to neutral to receive the control voltage from the first transformer; and

ii. a secondary coil having a first end and a second end, wherein the first end is electrically coupled to the phase;

wherein the primary coil and secondary coil are electromagnetically coupled to each other and so arranged that when the control voltage from the first transformer is applied to the first end and the second end of the primary coil, an output voltage is generated between the first end and the second end of the secondary coil;

wherein the output voltage is substantially 180°

out of phase from the input voltage so as to generate between the first end of the secondary coil and neutral an effective voltage that is less than the input voltage and substantially equals to the difference between the input voltage and the output voltage.

33. The system of claim 32, further comprising, on each phase, at least one load having a first terminal and a second terminal, wherein the first terminal is electrically coupled to the second end of the second transformer on the phase and the second terminal is electrically coupled to neutral to receive the effective voltage and generate a reduced power consumption.

34. The system of claim 32, further comprising:

a. a driver engaging the movable wiper arm through the body of the movable wiper arm of the first transformer on the phase; and

b. a controller, in control communication with the driver, causing the driver to move the movable wiper arm to a selected position between the second end and the first end of the winding, so that a control voltage with a selected value is generated between the output node and the second end of the winding of the first transformer on the phase.

35. The system of claim 34, wherein the controller is in control communication with each driver.

36. The system of claim 35, wherein the controller is programmable.

37. The system of claim 35, wherein the controller comprises a digital processor.

38. The system of claim 35, wherein the controller comprises an analog processor.

39. The system of claim 32, further comprising a user interface in communication with the controller.

40. The system of claim 39, wherein the user interface comprises a touchscreen having a plurality of settings, each setting including icons, each corresponding to a control signal that is communicated to the controller to cause at least one driver to move a corresponding movable wiper arm to a selected position, and displays, each displaying information associated with the operation of the system.

41. The system of claim 39, wherein the user interface is adapted to receive an input from a user and generate a control signal that is communicated to the controller to cause at least one driver to move a corresponding movable wiper arm to a selected position and to display to the user information associated with the operation of the system.

42. The system of claim 34, wherein the driver comprises a motor.

43. The system of claim 32, wherein the first transformer on each phase is a variable autotransformer having a capacity of output voltage ranging from 0 volts to approximately 220% of the input voltage.

44. The system of claim 32, wherein the second transformer on each phase is a buck transformer.

45. The system of claim 44, wherein the buck transformer is a torroidal transformer.

46. The system of claim 45, wherein the torroidal transformer has a ratio of 4:

1 (four to one) for the winding of the primary coil to the winding of the secondary coil.

48. The system of claim 47, wherein the first transformer of the power block comprises:

i. a winding having a first end and a second end, wherein the first end is electrically coupled to the input node and the second end is electrically coupled to neutral to receive the input voltage; and

ii. a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage.

49. The system of claim 48, wherein the power block further comprises:

a. a driver engaging the movable wiper arm through the body of the movable wiper arm; and

b. the controller, in control communication with the driver, causing the driver to move the movable wiper arm to a selected position between the second end and the first end of the winding, so that a control voltage with a selected value is generated between the output node and the second end of the winding.

50. The system of claim 49, wherein the first transformer is a variable autotransformer having a capacity of output voltage ranging from 0 volts to approximately 220% of the input voltage.

51. The system of claim 47, wherein the second transformer is a buck transformer.

52. The system of claim 51, wherein the primary coil and secondary coil of the buck transformer each has a polarity, and the polarity of the primary coil being reversed from the polarity of the secondary coil.

53. The system of claim 52, wherein the buck transformer is a torroidal transformer.

54. The system of claim 53, wherein the torroidal transformer has a ratio of 4:

1 (four to one) for the winding of the primary coil to the winding of the secondary coil.

55. The system of claim 47, wherein the controller is programmable.

56. The system of claim 55, wherein the controller comprises a digital processor.

57. The system of claim 55, wherein the controller comprises an analog processor.

58. The system of claim 47, wherein the control block further comprises a user interface in communication with the controller.

59. The system of claim 58, wherein the user interface comprises a touchscreen having a plurality of settings, each setting including icons, each corresponding to a control signal that is communicated to the controller to cause the system to perform a predetermined operation, and displays, each displaying information associated with the operation of the system.

60. The system of claim 58, wherein the user interface is adapted to receive an input from a user and generate a control signal that is communicated to the controller to cause the system to perform a predetermined operation and to display to the user information associated with the operation of the system.

61. The system of claim 47, wherein the control block further comprises a current transducer electrically coupled between the first power path and the controller for feeding current signal to the controller for monitoring the current passing through the first power path.

62. The system of claim 61, wherein the current transducer is a multi-channel current transducer, each channel being capable of monitoring current in a phase independently.

63. The system of claim 47, wherein the control block further comprises an input voltage transducer electrically coupled between the first power path and the controller and positioned between the input node and the power block for feeding input voltage signal to the controller for monitoring the input voltage applied to the power block.

64. The system of claim 47, wherein the control block further comprises an output voltage transducer electrically coupled between the first power path and the controller and positioned between the power block and the output node for feeding output voltage signal to the controller for monitoring the output voltage.

65. The system of claim 64, wherein the output voltage transducer is a multi-channel output voltage transducer, each channel being capable of monitoring voltage in a phase independently.

66. The system of claim 47, wherein the control block further comprises a first power supply device electrically coupled to the first power path for changing the input voltage to an AC voltage with a predetermined amplitude.

67. The system of claim 66, wherein the first power supply device comprises a transformer having a primary coil and a secondary coil, the primary coil being electrically coupled to the first power path for receiving the input voltage and the secondary coil outputting an AC voltage with a predetermined amplitude of substantially around 120 volts.

68. The system of claim 67, wherein the control block further comprises a second power supply device electrically coupled to the secondary coil of the first power supply device for changing the AC voltage with a predetermined amplitude of substantially around 120 volts to a DC voltage with a predetermined amplitude.

69. The system of claim 68, wherein the second power supply device comprises a transformer having a primary coil and a secondary coil, the primary coil being electrically coupled to the secondary coil of the first power supply device for receiving an AC voltage with a predetermined amplitude of substantially around 120 volts and the secondary coil outputting a DC voltage with a predetermined amplitude of substantially around 24 volts.

70. The system of claim 47, wherein the safety block further comprises a first circuit breaker electrically coupled between the first power path and the input node of the first transformer of the power block.

71. The system of claim 47, wherein the safety block further comprises a second circuit breaker electrically coupled between the output node of the first transformer of the power block and the primary coil of the second transformer of the power block.

72. The system of claim 47, wherein the safety block further comprises a relay device electrically coupled between the first transformer of the power block and the controller of the control block for receiving a DC signal from the controller during a normal operation of the system and providing an AC voltage to the first transformer of the power block during an abnormal operation of the system.

73. The system of claim 47, wherein the safety block further comprises a fusing device positioned on the first power path between the input node and the power block, the fusing device having a threshold of current at which the fusing device disconnects the system from the input node.

74. The system of claim 47, further comprising a second power path electrically coupling the input node and the output node, wherein the second power path is in parallel with the first power path.

75. The system of claim 74, wherein the safety block further comprises a switch operatively coupled to the first power path and the second power path for selectively allowing the current to flow therethrough one of the first power path and the second power path.

76. The system of claim 75, wherein the switch includes a switch having a first, a second and a third operative positions:

when the switch is selected to be on the first operative position corresponding to a first operation mode of the system, the switch allows the current to flow therethrough the first power path, the power block and the switch so that an output voltage different from the input voltage is generated between the output node and neutral;

when the switch is selected to be on the second operative position corresponding to a second operation mode of the system, the switch allows the current to flow therethrough the second power path and the switch so that an output voltage substantially identical to the input voltage is generated between the output node and neutral; and

when the switch is selected to be on the third operative position corresponding to a third operation mode of the system, the switch disallows the current to flow therethrough either of the first power path and the second power path so that no output voltage is generated between the output node and neutral.

47. A power regulation system coupled to an input node for receiving an input voltage and coupled to an output node for outputting an output voltage, comprising:

a. a first power path electrically coupling the input node and the output node to allow a current to flow therethrough;

b. a power block electrically coupled to the first power path and between the input node and the output node for regulating the current to flow therethrough the power block comprising;

i. a first transformer electrically coupled in parallel with the first power path, the first transformer having an input node and an output node; and

ii. a second transformer electrically coupled in series with the first power path, the second transformer having a primary coil and a secondary coil with reversed polarities,

wherein the input node of the first transformer is electrically coupled to the first power path for receiving the input voltage and the output node of the first transformer is electrically coupled to the primary coil of the second transformer for providing a control voltage to cause the secondary coil of the second transformer to generate an output voltage;

c. a control block electrically coupled to the first power path and in control communication with the power block for providing operating current and setting a control voltage for the power block, the control block comprising a controller in control communication with the first transformer of the power block for setting the control voltage at a selected voltage; and

d. a safety block electrically coupled to the first power path, the power block and the control block for providing surge protection, the safety block comprising;

i. a transient voltage suppression system electrically connected to the input node and positioned between the input node and the power block; and

ii. a shunt contactor electrically coupled across the primary coil of the second transformer of the power block.

77. A power regulation system coupled to a three-phase AC power source, each phase providing an input voltage related to neutral, respectively, comprising:

on each phase,

a. a first transformer, comprising;

i. a winding having a first end and a second end electrically coupled to the phase and neutral, respectively, to receive the input voltage from the phase; and

ii. a movable wiper arm having a wiper, an output node and a body therebetween, wherein the movable wiper arm is movable continuously between the second end and the first end of the winding so that a control voltage is generated between the output node and the second end within a range of from 0 volts to at least the input voltage; and

b. a second transformer, comprising;

i. a primary coil having a first end and a second end, wherein the first end is electrically coupled to the output node and the second end is electrically coupled to neutral to receive the control voltage from the first transformer; and

ii. a secondary coil having a first end and a second end, wherein the first end is electrically coupled to the phase;

c. a first circuit breaker electrically coupled between the phase and the first end of the winding of the first transformer;

d. a second circuit breaker electrically coupled between the output node of the first transformer and the primary coil of the second transformer; and

e. a shunt contactor electrically coupled across the primary coil of the second transformer,

wherein the first circuit breaker and the second circuit breaker are in parallel to each other and in series with the shunt contactor;

wherein the primary coil and secondary coil are electromagnetically coupled to each other and so arranged that when the control voltage from the first transformer is applied to the first end and the second end of the primary coil, an output voltage is generated between the first end and the second end of the secondary coil;

wherein the output voltage is substantially 180°

out of phase from the input voltage so as to generate between the first end of the secondary coil and neutral an effective voltage that is less than the input voltage and substantially equals to the difference between the input voltage and the output voltage.

78. The system of claim 77, further comprising, on each phase, at least one load having a first terminal and a second terminal, wherein the first terminal is electrically coupled to the second end of the second transformer on the phase and the second terminal is electrically coupled to neutral to receive the effective voltage and generate a reduced power consumption.

80. The method of claim 79, wherein the generating step comprises the steps of:

a. providing a controller in control communication with the first transformer;

b. operating the controller to generating a control signal responsive to a user input; and

c. applying the control signal to the first transformer so that the first transformer generates a control voltage corresponding to the user input at the output node of the first transformer.

81. The method of claim 80, further comprising:

a. providing a user interface in communication with the controller; and

b. inputting user input to the controller through the user interface.

82. The method of claim 81, wherein the user interface includes a touchscreen having a plurality of settings, each setting including icons, each corresponding to an input signal to cause the controller to generate a predetermined control signal, and displays each displaying information associated with the operation of the system, further comprising:

a. selecting a sequence of settings in conjunction with the touchscreen for programming the controller; and

b. monitoring the operation of the power regulation system through the touchscreen.

79. A method of regulating power to a load in conjunction with a power regulation system having a power path, a first transformer electrically coupled in parallel with the power path, the first transformer having an input node and an output node, and a second transformer electrically coupled in series with the power path, the second transformer having a primary coil and a secondary coil, wherein the input node of the first transformer is electrically coupled to the power path and the output node of the first transformer is electrically coupled to the primary coil of the second transformer, comprising the steps of:

a. providing an input voltage through the power path to the input node of the first transformer;

b. generating a control voltage at the output node of the first transformer; and

c. applying the control voltage to the primary coil of the second transformer to cause the secondary coil of the second transformer to generate an output voltage that is substantially 180°

out of phase from the input voltage so as to generate an effective voltage applied to the load, wherein the effective voltage is less than the input voltage, resulting a reduction in power consumption of the load.

83. A power regulation system for regulating power to a load having a power path, a first transformer electrically coupled in parallel with the power path, the first transformer having an input node and an output node, and a second transformer electrically coupled in series with the power path, the second transformer having a primary coil and a secondary coil, wherein the input node of the first transformer is electrically coupled to the power path and the output node of the first transformer is electrically coupled to the primary coil of the second transformer, comprising:

a. means for providing an input voltage through the power path to the input node of the first transformer;

b. means for generating a control voltage at the output node of the first transformer; and

c. means for applying the control voltage to the primary coil of the second transformer to cause the secondary coil of the second transformer to generate an output voltage that is substantially 180°

out of phase from the input voltage so as to generate an effective voltage applied to the load, wherein the effective voltage is less than the input voltage, resulting a reduction in power consumption of the load.

84. The system of claim 83, further comprising:

a. means for generating a control signal responsive to a user input, wherein the generating means in control communication with the first transformer; and

b. means for applying the control signal to the first transformer so that the first transformer generates a control voltage corresponding to the user input at the output node of the first transformer.

85. The system of claim 84, further comprising means for inputting user input to the means for generating a control signal responsive to a user input.

86. The method of claim 85, wherein means for inputting user input comprises:

a. means for selecting a sequence of settings to program the means for generating a control signal responsive to a user input; and

b. means for monitoring the operation of the power regulation system.

87. A computer program product in a computer readable medium of instructions, comprising:

a. instructions within the computer readable medium for operating a controller that is in communication with an user interface and a first transformer coupled to a power path for receiving an input voltage at an input node of the first transformer; and

b. instructions within the computer readable medium for permitting input to the controller by a user to generate a control signal responsive to the input; and

c. instructions within the computer readable medium for applying the control signal to the first transformer so that the first transformer generates a control voltage corresponding to the input at an output node of the first transformer, wherein the first transformer is electrically coupled with a second transformer that is coupled to the power path and has a primary coil coupled to the output node of the first transformer and a secondary coil so that when the control voltage is applied to the primary coil of the second transformer, the secondary coil of the second transformer generates an output voltage that is substantially 180°

out of phase from the input voltage.

88. The computer program product of claim 87, further comprising instructions within the computer readable medium for programming the controller responsive to user inputs.

89. The computer program product of claim 87, further comprising instructions within the computer readable medium for monitoring operation along the power path and generating operation data in the controller.

90. The computer program product of claim 89, further comprising instructions within the computer readable medium for displaying the operation data in the user interface.