Actuator Control Device Integrating Voltage Detection and Adjustable Limit Switches

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Solution Overview

Problem

Conventional actuator control devices face issues with hidden limit switches that cannot be adjusted, high current damage, complex wire layouts, unreliable voltage detection, and increased costs due to external control circuits, leading to potential mechanical damage and operational inefficiencies.

Innovation Solution

An integrated control device within the actuator combines a limit switch control unit and a voltage detection unit, eliminating the need for external circuits, allowing adjustable limit switches to prevent high current damage and detecting voltage ranges to protect the actuator from excessive voltages, while reducing wire complexity and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hidden-type mechanical limit switches are used in conventional actuators, then the limit switches are protected from external damage, but their positions cannot be adjusted according to actual requirements

Engineering Contradiction:

Improvelimit switch protectionVSAvoidlimit switch position adjustment

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The actuator is divided into separate functional modules: the limit switches are positioned externally on the actuator body while the control circuit is integrated inside. This segmentation allows the limit switches to be independently positioned and adjusted without affecting the internal control system, resolving the contradiction between protection and adjustability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A control circuit is introduced as an intermediary between the limit switches and the motor control system. This control circuit receives signals from the limit switches and processes them to control motor operation, enabling external limit switches to function reliably while maintaining adjustability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If limit switches are used in conventional control devices, then the travel of the actuating member is restricted, but high current flows through the limit switch contacts causing damage

Engineering Contradiction:

Improvetravel restriction functionVSAvoidlimit switch contact lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The control circuit serves as an intermediary that receives low-current signals from the limit switches and uses these signals to control the high-current motor circuit. This intermediary function protects the limit switch contacts from high current damage while maintaining the travel restriction function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct mechanical-electrical connection between limit switches and motor control is replaced with an electronic control system. The limit switches generate electrical signals that are processed by the control circuit, substituting the direct high-current mechanical contact with an electronic signaling system that preserves contact lifespan.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If external connection wires are used to connect limit switches to motor control circuit, then the limit switch positions are freely adjustable, but the wire layout becomes complicated affecting appearance and security

Engineering Contradiction:

Improvelimit switch position flexibilityVSAvoidwire layout complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control circuit is merged with the actuator housing, integrating the wiring connections inside the actuator body. Only necessary power and control wires need to enter the actuator, while the limit switches can be positioned externally without requiring complex external wire routing, thus simplifying the overall wire layout while maintaining position flexibility.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If additional control circuit is added to control limit switches and detect voltage, then the actuator has complete control function, but the cost increases

Engineering Contradiction:

Improvecontrol function completenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The control circuit is designed to perform multiple functions: it processes limit switch signals for travel restriction, detects input voltage levels for motor protection, and controls motor operation. This multi-functional design consolidates what would otherwise require separate circuits into a single integrated unit, reducing component count and manufacturing cost while maintaining complete control functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7944672B1Control device for an actuator

Publication Date: 2011.05.17 HIWIN MIKROSYST

AI summary

A control device applicable to an actuator and including a voltage detection unit and a limit switch control unit. The control device is inbuilt inside the actuator without any additional control circuit for the control of the limit switches and the detection of the input voltage range. The limit switches are used to limit the travel of an actuating member of the actuator so as to avoid collision of the mechanism. The voltage detection unit serves to detect the input voltage range to control the operation of the actuator. Accordingly, the mechanism or the motor is protected from damage due to excessively low or high input voltage. The limit switches are freely adjustable in position and protected from high current. Therefore, the contacts of the limit switches are not liable to damage and the lifetime of the limit switches is prolonged. The control device further has electronic brake effect.