The main power supply in most homes and businesses is accessed by plugging a device into a wall outlet. This power supply can be referred to in a variety of different ways including, for example, as wall power, grid power, household electricity, line power, AC power, AC mains, and so on. Electrical equipment and/or devices plugged into the “AC mains” can have varying power consumption profiles. While different devices can pull greater or lesser amounts of current, some devices can have more complicated power consumption cycles that can cause fluctuations in the amount of current being drawn from the AC mains. Fluctuations in current through the AC mains circuitry can cause the voltage to change at the same rate as the fluctuating current. Changes in the voltage can cause the dimming or flickering of lights plugged into the AC mains, referred to as flicker. Such voltage changes on the AC mains can be problematic for sensitive electronic equipment and for people who have photosensitive eyes and other health issues.
Examples will now be described with reference to the accompanying drawings, in which:
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
International electro-technical (IEC) standards specify limits on the level of voltage change, or flicker, that can be caused by an electrical appliance/device operating on the AC mains power supply. Flicker is caused by load changes within a device that occur in a mostly step-wise fashion over short time periods. Products are tested to ensure compliance with the standards, and many international markets that recognize these requirements, such as the European Union, the United Kingdom and other countries, prohibit the shipment and sale of products that do not meet the IEC standards. A flicker meter, as defined by an IEC standard, can be used to determine a short term flicker “perceptibility” value, referred to as Pst. Several Pst values determined over a longer time period can be used to determine a long term flicker “perceptibility” value, referred to as Plt. The relevant IEC flicker standard presently limits the value of Pst to 1.0 over an observation period of 10 minutes, and the value of Plt to 0.65 over an observation period of 2 hours.
Three-dimensional (3D) printing devices are one example of an electrical appliance that can utilize large amounts of electrical power in an uneven and repeatable (i.e., cyclical) manner that can cause fluctuations in the AC mains power supply. In some 3D printing devices, for example, increased electrical power can be used to generate heat in a cyclical process that can fuse plastic and other materials into layers of a 3D part, one layer at a time. Such devices can vary their operating power instantaneously by activating and deactivating large loads, such as heating lamps, to achieve high part quality and throughput. In some examples, the resulting fluctuations in AC mains power caused by such devices can conflict with the international regulatory standards.
In some examples of product development, consideration for how a device can meet the IEC standards for AC mains voltage fluctuation is left to the end of the product development cycle. The result can lead to inadequate solutions and costly delays with respect the introduction of products into some international markets. Some solutions for meeting the IEC standards have included slowing down power fluctuations within a device to meet regulatory requirements, balancing the switching of large loads to minimize overall AC mains power fluctuations, and adding hardware to buffer the AC mains from the device power fluctuations. In some examples, however, these types of solutions can have certain drawbacks. Slowing down power fluctuations, for example, can cause poor performance in devices such as 3D printers, by reducing 3D part throughput and quality. Balancing the switching of large loads in a device can involve the use of complex firmware synchronization of loads, and a lack of flexibility to adapt to changes in device power requirements to maintain quality. Adding hardware to buffer the AC mains from device power fluctuations can result in excessive cost and complexity in a device.
Accordingly, examples of a power management system and methods are described herein that compensate for instantaneous power fluctuations in devices operating from an AC mains power supply. The power management system enables devices such as 3D printers to meet IEC “flicker” regulatory standards while not interfering with the device operations that can involve the activation and deactivation of large loads that can cause such fluctuations in power.
A controller of a power management system can anticipate the moment a large device load will be activated. Prior to activating the device load, the controller can initiate and manage a gradual ramping up of AC mains current (e.g., over several seconds) through a compensation load that is in parallel with the device load. Upon activation of the device load, a control loop of the power management system senses an abrupt increase in the AC mains current and counters this increase by turning off the compensation load instantly (e.g., over a time period on the order of microseconds), which reroutes the ramped up AC mains current from the compensation load to the parallel device load. The virtually instantaneous manner in which the compensation load is turned off and “replaced” by the device load helps to avoid a fluctuation in the AC mains current.
Upon deactivation of the device load, the control loop senses an abrupt decrease in the AC mains current and counters this decrease by turning on the compensation load instantly (e.g., over a time period on the order of microseconds), which reroutes the ramped up AC mains current from the deactivated device load back to the parallel compensation load. The virtually instantaneous manner in which the compensation load is turned back on to “replace” the deactivated device load, again, helps to avoid a fluctuation in the AC mains current. Once the device load is deactivated, the controller can initiate and manage a gradual ramping down of AC mains current (e.g., over several seconds) with a gradual decrease in the compensation load. The process of gradually ramping up and gradually ramping down the AC mains current in this manner can occur repeatedly with each cycle of activation and deactivation of a device load, thereby reducing fluctuations in the AC mains current and voltage that may otherwise violate IEC “flicker” regulatory standards.
In one example, a method of power management includes, prior to activating a device load, gradually increasing a compensation load in parallel with the device load to increase AC mains current to a current set point. The method includes activating the device load, and sensing the activation of the device load. Upon sensing activation of the device load, the compensation load is reduced to maintain the AC mains current at the current set point.
In another example, a power management system includes a device to implement a cyclical device load. The system includes a controller to increase AC mains current into the device to a current set point in anticipation of activating the device load. Increasing the AC mains current can be achieved by increasing a compensation load in parallel with the device load. A control loop in the power management system is to sense activation of the device load, and in response to the sensing, to turn off the compensation load to avoid an increase in the AC mains current beyond the current set point. In some examples, the control loop can sense a subsequent deactivation of the device load, and turn on the compensation load again to avoid a decrease in the AC mains current below the current set point. Thereafter, the controller can decrease the AC mains current into the device back down to a quiescent current level.
In another example, a non-transitory machine-readable storage medium stores instructions that when executed by a processor of a power management system causes the power management system to anticipate activating a device load, and prior to activating the device load, gradually increasing AC mains current through a compensation load in parallel with the device load. The instructions further cause the system to activate the device load after the AC mains current has reached a predetermined current set point, deactivate the device load, and then to gradually decrease the AC mains current through the compensation load from the current set point down to a quiescent current level.
Referring to
A memory 114 can include both volatile (i.e., RAM) and nonvolatile memory components (e.g., ROM, hard disk, optical disc, CD-ROM, magnetic tape, flash memory, etc.). The components of memory 114 comprise non-transitory, machine-readable (e.g., computer/processor-readable) media that can provide for the storage of machine-readable coded program instructions, data structures, program instruction modules, JDF (job definition format), and other data and/or instructions executable by a processor 112 of the 3D printing device 106. Examples of executable instructions to be stored in memory 114 include instructions associated with a device function module 116, a load anticipation module 118, and a load activation module 120. In general, modules 114, 116, and 118, include programming instructions and/or data executable by a processor 112 to cause the 3D printing device 106 to perform operations related to processing and generating 3D parts, and to control the power management system 100 to manage power fluctuations within the device 106 to avoid abrupt changes in AC mains current from the AC mains power supply 102. Such operations can include, for example, the operations of methods 600 and 700, described below with respect to
Referring still to
An agent distributor 126 can deliver a fusing agent and/or a detailing agent in a selective manner onto portions of a layer of build material provided on support member 122. An agent distributor 126 can be implemented, for example, as one or multiple printheads, such as thermal inkjet printheads or piezoelectric inkjet printheads. As shown in
The heat lamp 104 comprises a cyclical device load 104 that can be activated and deactivated within a single 3D printing process cycle to form a layer of a 3D part. For example, when forming a layer of a 3D part, the controller 108 can execute instructions from 3D print function module 116 to cause the material distributor 124 to deposit a layer of build material onto the support member 122. The controller 108 can additionally cause the agent distributor 126 to deliver a fusing agent onto portions of the layer of build material. Executing instructions from the load activation module 120, the controller 108 can activate and deactivate the heat lamp 104 at appropriate times within each process cycle to generate heat that can melt and solidify the layer. Thus, performing a single 3D printing process cycle comprises depositing and processing a single layer of build material in this general manner. Because the formation of a 3D part involves the processing of many layers, one after another, the heat lamp 104 behaves as a cyclical device load 104 that is activated and deactivate within each process cycle. The cyclical activation and deactivation of the large device load 104 can generate power fluctuations within the device 106 that cause current and voltage fluctuations (i.e., flicker) within the AC mains power supply 102.
As noted above, an example power management system 100 can include a control loop 110.
After the AC mains current, IMains, reaches the current set point, the controller 108 can activate the device load 104 (Plot #2,
As shown in
After the controller 108 deactivates the device load 104, it can begin to gradually ramp down (i.e., decrease) the AC mains current, IMains, from the current set point to a quiescent current level as shown in Plot #1 of
The methods 600 and 700 may include more than one implementation, and different implementations of methods 600 and 700 may not employ every operation presented in the respective flow diagrams of
Referring now to the flow diagram of
Continuing at block 608, the method 600 can include activating the device load. In some examples, activating the device load can include activating a heat lamp in a 3D printing device, as shown at block 610. As shown at block 612, upon sensing activation of the device load, the compensation load can be decreased to maintain the AC mains current at the current set point. Decreasing the compensation load can include turning off the compensation load over a time period whose duration spans a number of microseconds, as shown at block 614. The method can continue at block 616, with deactivating the device load. As shown at block 618, upon sensing deactivation of the device load, the compensation load can be increased to maintain the AC mains current at the desired current set point.
After increasing the compensation load to maintain the AC mains current, the method can include gradually decreasing the compensation load to decrease the AC mains current to a quiescent current level, as shown at block 620. In some examples, as shown at block 622, gradually decreasing the compensation load can include comparing first and second voltages with a voltage error amplifier, where the first voltage comprise a VActual voltage across a first resistor through which the AC mains current flows, and the second voltage comprises a VDesired voltage at the output of a voltage divider coupled to the AC mains. Gradually decreasing the compensation load can also include adjusting a resistor in the voltage divider to decrease VDesired, causing the voltage error amplifier to decrease the compensation load to keep VActual equal to VDesired.
Referring now to the flow diagram of
The method can continue as shown at block 706, with gradually increasing AC mains current through a compensation load in parallel with the device load, prior to activating the device load. As shown at block 708, the method can include activating the device load after the AC mains current has reached a predetermined current set point. In some examples, activating the device load can include turning on a heating lamp in a 3D printing device, as shown at block 710. The method can further include deactivating the device load, as shown at block 712, where the deactivating of the device load includes turning off the heating lamp after a layer of build material on a support member of the 3D printing device has been heated, as shown at block 714. As shown at block 716, the method can also include gradually decreasing the AC mains current through the compensation load from the current set point down to a quiescent current level.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/058889 | 10/26/2016 | WO | 00 |