Electromagnetic angle valve circuit capable of being started at high power and kept at low power

Abstract

The invention discloses a high-power-on and low-power-keeping electromagnetic angle valve circuit, which comprises a power supply module for providing a stable direct-current power supply and controlling the on-off of external alternating current; the electromagnetic coil module is used for realizing the connection of coils in a series connection manner and generating electromagnetic force through current to drive a valve core to move; the timing switching module is used for accurately timing and realizing short circuit or access of a coil by controlling the conduction or cut-off of an MOS (Metal Oxide Semiconductor) tube so as to complete the switching between high power and low power; and the in-place detection module is used for detecting whether the valve is opened in place or not and feeding back a state signal to an external control system. Through dynamic power switching of high-power opening and low-power keeping, energy consumption in the keeping stage is greatly reduced while it is guaranteed that the valve is rapidly and thoroughly opened, and the service life of a coil is prolonged.

Description

Technical Field

[0001] This invention relates to the field of fluid control technology, and in particular to an electromagnetic angle valve circuit that enables high-power opening and maintains low-power operation. Background Technology

[0002] Electromagnetic angle valves are key actuators in the field of fluid control, widely used in industrial automation, fluid pipeline control, and other scenarios. Their core function is to control the opening and closing of fluid passages by driving the valve core with electromagnetic force. Currently, the traditional electromagnetic angle valves in the industry mainly adopt a single-power drive scheme, that is, the entire process from valve opening to maintaining the open state is driven by the same amount of electrical energy to operate the electromagnetic coil.

[0003] The specific technical solutions can be divided into two categories: 1. High-Power Single-Drive Scheme: To ensure reliable valve opening despite valve core friction and fluid resistance, a high drive power (achieved through high voltage or high current) is designed, and this power is maintained to drive the coil even after the valve is opened. For example, an industrial electromagnetic angle valve uses 220V AC to directly drive the coil, with a fixed coil resistance of 100Ω and a constant operating current of 2.2A. The total power from opening to holding is approximately 484W. The disadvantages of this scheme are: excessive energy consumption during the holding phase, leading to increased operating costs over long-term operation; and the coil being under high current and high temperature conditions for extended periods, causing the insulation layer to age easily and shortening its lifespan (typically 30%-50% shorter than low-power operation).

[0004] 2. Low-power single-drive scheme: To reduce operating energy consumption, a lower drive power is designed, achieved by reducing the coil operating voltage or current. For example, a small electromagnetic angle valve uses 12V DC drive, with a coil resistance of 50Ω, an operating current of 0.24A, and a total power of approximately 2.88W. The disadvantage of this scheme is that the electromagnetic force is insufficient during the opening phase, which can easily lead to valve opening delay (delay time exceeding 1 second) and incomplete opening (valve core not fully in place), affecting fluid control accuracy and even causing system pressure instability.

[0005] In addition, while some existing technologies attempt to resolve the "power contradiction between opening and holding," such as magnetic angle valves, mechanical timers are approximately 5cm×3cm×2cm in size, and their timing errors are typically above ±50ms. Other solutions employ circuit switching without state feedback: a simple RC delay circuit controls a relay to switch the coil power supply voltage, but lacks a detection mechanism to determine whether the valve is in position, making it impossible to judge the actual working state of the valve. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides an electromagnetic angle valve circuit that enables high-power operation while maintaining low-power operation.

[0007] This invention is achieved using the following technical solution: an electromagnetic angle valve circuit with high-power opening and low-power holding, comprising: The power supply module is used to provide a stable DC power supply and control the on / off state of the external AC power. The electromagnetic coil module uses a series connection of coils and generates electromagnetic force through current to drive the valve core to move. The timing switching module is used for precise timing and controls the conduction or cutoff of the MOSFET to short-circuit or connect the coil, thereby completing the switching between high and low power. The position detection module is used to detect whether the valve is fully opened and to send a status signal back to the external control system.

[0008] Furthermore, the power supply module includes a DC power supply and an onboard relay. The DC power supply is connected to the onboard relay, and the onboard relay is connected to the electromagnetic coil module through a rectifier bridge. When the DC power supply is turned on, the onboard relay is energized, the contacts close, and external AC power is connected. When the power is turned off, the contacts open, cutting off the AC power.

[0009] Furthermore, the electromagnetic coil module has a low-resistance coil 1 and a high-resistance coil 2 connected in series, and the series node is connected to the drain of the MOS transistor of the timing switching module through a wire.

[0010] Furthermore, both the low-resistance coil 1 and the high-resistance coil 2 are wound with enameled copper wire, wherein the number of turns of the high-resistance coil 2 is greater than the number of turns of the low-resistance coil 1; the low-resistance coil 1 is used for high-power switching, and the high-resistance coil 2 is used for low-power holding.

[0011] Furthermore, the timing switching module includes a timer, an isolation optocoupler, and a MOSFET. The input terminal of the timer is connected to the power supply module, and the output terminal is connected to the isolation optocoupler. The output terminal of the isolation optocoupler is connected to the gate of the MOSFET.

[0012] Furthermore, the positioning detection module includes a reed switch, which is positioned within the magnetic field range generated by the electromagnetic coil module. When the valve is fully opened, the coil magnetic field attracts the reed switch contacts, outputting a low level; when the valve is not fully opened, the reed switch is disconnected, outputting a high level.

[0013] The beneficial effects of this invention are as follows: 1. Significantly reduced energy consumption and extended coil life. Utilizing a high-power turn-on (7.4A, 400ms) + low-power hold (0.16A, continuous) drive mode, the hold current is reduced to the milliampere level. Compared to traditional high-power single-drive solutions (7.4A throughout), energy consumption is reduced by over 80%; the coil avoids prolonged high-temperature operation, extending its lifespan by over 50%.

[0014] 2. Reliable valve opening and high control precision. During the high-power opening phase, coil 1 generates a large current of 7.4A, and the strong electromagnetic force quickly overcomes the valve core resistance; the 555 timer accurately times the valve at 400ms, ensuring accurate power switching timing. This solves the problems of "opening delay and incomplete opening" in traditional low-power single-drive solutions. The valve opening response time is ≤400ms, and the opening success rate is increased to over 99.9%.

[0015] 3. Timely status feedback and efficient fault diagnosis. The valve's position status is monitored in real time via a reed switch, outputting high and low level signals to the external control system. Compared to traditional feedback-less solutions, this allows for rapid identification of problems such as "valve core jamming" and "coil failure," reducing fault diagnosis time to less than 1 second and preventing system accidents caused by misjudgments.

[0016] 4. Simple and reliable structure, low cost. Utilizing mature components (NE555, GBU1510, HCPL-3120-500E), it eliminates the need for complex mechanical structures or multiple relays; anti-interference capability is enhanced through optocoupler isolation. The overall circuit size is 30% smaller than traditional mechanical timer solutions, and component costs are reduced by 20%; anti-interference capability is improved, and the long-term failure rate is reduced to below 0.5%. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 This is a block diagram illustrating the principle of the present invention; Figure 2 This is a schematic diagram of the circuit connection between the power supply module and the electromagnetic coil module; Figure 3 This is a circuit connection diagram for the timer; Figure 4 This is a schematic diagram of the circuit connection between the isolation optocoupler and the MOSFET; Figure 5 This is a schematic diagram of the signal output of the position detection module. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0021] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0022] See Figure 1 A high-power opening and low-power holding electromagnetic angle valve circuit includes: a power supply module, an electromagnetic coil module, a timing switching module, and a position detection module. Through the coordinated work of the power supply module, electromagnetic coil module, timing switching module, and position detection module, the valve can achieve "high-power opening, low-power holding, and real-time status feedback".

[0023] For details, see Figure 2 The power supply module is mainly used to provide a stable DC power supply to power the electromagnetic coil and other modules, and to control the on / off state of the external AC power. Its components and parameters are as follows: 24V DC power supply: A linear regulated power supply with an output voltage accuracy of ±0.5V, providing the operating voltage for the onboard relay. Onboard relay: Model G5Q-14, rated contact voltage 250VAC, rated contact current 10A, normally in a closed state; when the 24V power supply is on, the relay coil is energized, the contacts close, and the external 220V AC power is connected; when the power is off, the contacts open, cutting off the AC power.

[0024] In addition, the power supply module also includes a rectifier bridge: model GBU1510, with a maximum forward rectified current of 15A and a maximum reverse withstand voltage of 1000V. It can rectify 220V AC power into pulsed DC power with an average voltage of 200V to power the electromagnetic coil module.

[0025] The electromagnetic coil module generates electromagnetic force through current to drive the valve core. High- and low-power switching is achieved through coil series / short-circuit switching. Its components and parameters are as follows: Low-resistance coil 1: wound with enameled copper wire, 860 turns, resistance 27Ω (low resistance, high current carrying capacity, used for high-power activation). High-resistance coil 2: wound with enameled copper wire, 2440 turns, resistance 1183Ω (high resistance, used for low-power holding). Connection method: Coil 1 and coil 2 are connected in series, and the series connection point is connected to the drain (D) of the N-channel MOSFET in the timing switching module via a wire.

[0026] This invention employs a "series dual coil + MOSFET short-circuit" power switching mechanism: a low-resistance coil 1 (27Ω, high-power turn-on) and a high-resistance coil 2 (1183Ω, low-power hold) are connected in series. Power switching is achieved by controlling the short circuit / connection of coil 2 through the on / off state of the MOSFET. Compared to traditional single-power switching (difficult to balance reliability and energy consumption) and mechanical switching (requires additional resistors and has low accuracy), this structure requires no additional components, is small in size, and provides precise switching with no energy loss.

[0027] See Figure 3 and Figure 4 The timing switching module is mainly used for precise 400ms timing, controlling the on / off state of the N-channel MOSFET, and achieving short-circuiting / connection of coil 2 to complete high- and low-power switching. Its components and parameters are as follows: 555 Timer: Model NE555 chip, external precision resistor R (36.4kΩ) and surface-mount capacitor C (10μF). Based on the timing formula t=1.1RC, the timing duration is 400.4ms (error ≤1ms). When a 200V pulse DC power supply is input, the timer starts working, outputs a high level for 400ms, and then stops outputting. Isolation Optocoupler: Model HCPL-3120-500E, with an output saturation voltage drop <0.2V when the input current is 9mA; the input terminal is connected to the output terminal of the 555 timer, and the output terminal is connected to the gate (G) of the N-channel MOSFET, achieving high- and low-voltage circuit isolation to avoid interference. N-channel MOSFET: Model IRFP360PBF, withstand voltage 360V, rated current 23A; source (S) connected to the negative terminal of 200V pulsed DC power, drain (D) connected to the series node of coil 1 and coil 2; when the gate (G) is high, the MOSFET is turned on and coil 2 is short-circuited; when the gate is not high, the MOSFET is turned off and coil 2 is connected to the circuit.

[0028] This invention employs a 555 timer for millisecond-level timing: the NE555, paired with a 36.4kΩ resistor and a 10μF capacitor, achieves 400ms timing (error ≤1ms), precisely matching the valve opening duration. Traditional mechanical timing (error ±50ms+) and RC delay (error ±20ms+) lack sufficient accuracy. This solution avoids the problem of switching too early / too late, ensuring reliable power switching. High-low voltage isolation via optocoupler: An HCPL-3120-500E optocoupler is connected between the 555 timer (low voltage 5V) and the MOSFET (high voltage 200V) to block high-low voltage crosstalk. Traditional solutions without isolation are prone to damage to the control chip and signal malfunction. This design improves anti-interference capabilities and extends component lifespan.

[0029] See Figure 5 The valve position detection module is used to detect whether the valve is fully open and to send a status signal back to the external control system. Its components and parameters are as follows: Reed switch: Model MDRR-DT, operating distance 5-10mm, positioned within the magnetic field range generated by the electromagnetic coil module; when the valve is fully open, the coil magnetic field attracts the reed switch contacts, outputting a low level (0V); when the valve is not fully open, the reed switch disconnects, outputting a high level (24V). Signal transmission: The reed switch output is connected to the signal receiver of the external control system via a wire to transmit the status signal in real time.

[0030] This invention employs real-time reed switch positioning detection: the MDRR-DT reed switch is placed in the coil's magnetic field; when the valve is in position, it is activated and outputs a low level (0V); when not in position, it outputs a high level (24V). Traditional feedback-free solutions rely on timing judgments, which are prone to misjudgment. This mechanism eliminates the need for complex sensors, enabling rapid fault identification and improving safety. High-performance component selection: the MOSFET is selected as IRFP360PBF (360V withstand voltage, 23A current), and the rectifier bridge is selected as GBU1510 (15A current, 1000V withstand voltage), suitable for 200V, 7.4A high-power conditions. Traditional components (MOSFET withstand voltage <100V, rectifier bridge current <5A) are prone to overload damage; this selection ensures no overload risk.

[0031] The overall workflow of this invention is as follows: During the high-power start-up phase (0-400ms), the external control system issues a start-up command, energizing the 24V DC power supply → the onboard relay coil is energized and the contacts close → 220V AC power is connected to the rectifier bridge → the rectifier bridge outputs 200V pulsed DC power.

[0032] Simultaneously, the 555 timer starts working, outputting a 400ms trigger signal → the signal is transmitted to the gate (G) of the MOSFET via the isolation optocoupler → the source (S) and drain (D) of the MOSFET are turned on → coil 2 is short-circuited (current does not pass through coil 2). The 200V pulsed DC current only acts on coil 1 → the circuit current I1 = 200V / 27Ω ≈ 7.4A (large current) → coil 1 generates a strong electromagnetic force, quickly pulling up the valve core, thus opening the valve. In the low-power hold phase (after 400ms), the 555 timer finishes timing 400ms and stops outputting a high level → the isolation optocoupler has no signal output → the gate (G) of the MOSFET is de-energized, and the source (S) and drain (D) are cut off → coil 2 is reconnected to the circuit (coil 1 and coil 2 are connected in series). Total resistance R_total = 27Ω + 1183Ω = 1210Ω → Circuit current I2 = 200V / 1210Ω ≈ 0.16A (milliampere level current) → The coil generates electromagnetic force to maintain the valve core position and achieve low power holding.

[0033] During the valve positioning detection phase (full process), if the valve is fully open, the coil magnetic field attracts the reed switch, resulting in a low-level output. The external control system receives the "positioned" signal, confirming that the valve is operating normally. If the valve is not fully open (e.g., the valve core is stuck), the coil magnetic field is insufficient, the reed switch remains open, and a high-level output continues. The external control system identifies the "not in position" fault and triggers a secondary drive or alarm.

[0034] Based on the above embodiments, the present invention can achieve at least the following technical effects: 1. Resolve the contradiction between energy consumption and opening reliability: By dynamically switching between "high power opening and low power holding", the energy consumption during the holding phase is significantly reduced while ensuring the valve opens quickly and completely, thus extending the coil's service life.

[0035] 2. Solve the problem of "low timing accuracy": Use a 555 timer as the timing reference, combined with precision resistors and capacitors, to achieve precise timing at the millisecond level (error ≤1ms), ensuring that the power switching timing is perfectly matched with the valve opening time.

[0036] 3. Solve the problem of "no status feedback": The valve position status is detected by a reed switch, and high and low level signals are output in real time, which makes it easier for the external control system to judge whether the valve is open normally, avoiding misoperation and failure to be missed.

[0037] 4. Solve the problems of "complex structure and poor anti-interference": Use integrated components (such as GBU1510 rectifier bridge and NE555 timer) to simplify the circuit structure; use isolation optocouplers to achieve isolation between high and low voltage circuits, improve anti-interference ability, and ensure long-term stable operation.

[0038] For the foregoing embodiments, in order to simplify the description, they are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, because according to this application, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to this application.

[0039] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. A high power on, low power hold open solenoid angle valve circuit, characterized by, The utility model relates to a valve drive system, which comprises: a power supply module for providing stable DC power and controlling the on-off of external AC power; an electromagnetic coil module for connecting coils in series and generating electromagnetic force through current to drive the movement of a valve core; a timing switching module for precise timing and realizing the short circuit or connection of coils by controlling the conduction or cut-off of MOS tubes to complete the switching of high and low power; a position detection module for detecting whether the valve is opened to the position and feeding back a state signal to an external control system.

2. An electromagnetic angular valve circuit with high power opening and low power holding according to claim 1, characterized in that The power supply module comprises a DC power supply and a board-mounted relay, the DC power supply is connected with the board-mounted relay, and the board-mounted relay is connected with the electromagnetic coil module through a rectifier bridge; when the DC power supply is turned on, the board-mounted relay is powered, the contact is attracted, and external AC power is connected; when the power is off, the contact is disconnected, and the AC power is cut off.

3. A high power on, low power hold open solenoid valve circuit as defined in claim 1 wherein, The electromagnetic coil module comprises a low-resistance coil 1 and a high-resistance coil 2, the low-resistance coil 1 and the high-resistance coil 2 are connected in series, and the series node is connected to the drain of a MOS tube of the timing switching module through a wire.

4. An electromagnetic angular valve circuit with high power opening and low power holding according to claim 3, characterized in that The low-resistance coil 1 and the high-resistance coil 2 are both wound with enameled copper wire, the number of turns of the high-resistance coil 2 is greater than that of the low-resistance coil 1, the low-resistance coil 1 is used for high-power opening, and the high-resistance coil 2 is used for low-power keeping.

5. A high power on, low power hold open solenoid valve circuit as defined in claim 1 wherein, The timing switching module comprises a timer, an isolation optocoupler and a MOS tube, the input end of the timer is connected with the power supply module, the output end is connected with the isolation optocoupler, and the output end of the isolation optocoupler is connected with the gate of the MOS tube.

6. A high power on, low power hold open solenoid valve circuit as defined in claim 1 wherein, The position detection module comprises a reed switch, the reed switch is arranged in the magnetic field range generated by the electromagnetic coil module, when the valve is opened to the position, the coil magnetic field attracts the contact of the reed switch, and a low level is output; when the valve is not in position, the reed switch is disconnected, and a high level is output.

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