Actuator Controller Failsafe Power Circuit
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Solution Overview
Problem
Existing vehicular actuator controllers fail to controllably supply DC power to bi-directional electromechanical actuators, such as DC motors, especially during vehicle system failures like unexpected loss of electrical power or communication loss with the remote electronic control unit, leading to potential clutch malfunctions and increased manufacturing costs due to complex designs and quality defects.
Innovation Solution
An actuator controller with a microcontroller that receives power and direction command signals, determines system failures, and generates a failsafe position command to store and supply electrical power using a failsafe power circuit, including a storage capacitor and boost/buck circuits, ensuring continued operation of the electromechanical actuator even in failure scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a failsafe power circuit with storage capacitor and boost/buck circuits is added to maintain actuator functionality during power failures, then reliability is improved, but device complexity increases
Solution Approach 1:
The failsafe power circuit pre-charges the storage capacitor during normal operation before a power failure occurs. This preliminary energy storage ensures that the actuator can be immediately actuated to a safe position without waiting for external power to be restored, thereby maintaining reliability while managing complexity through advance preparation.
Solution Approach 2:
The storage capacitor acts as an intermediary energy buffer between the main power source and the actuator. During normal operation, it stores energy; during power failure, it releases energy to maintain actuator functionality. This intermediary component resolves the contradiction by providing a simple energy storage mechanism that improves reliability without requiring complex real-time power management circuits.
2Adaptability or versatility
If separate external locking members and slide plate are added to create controllable OWC, then adaptability is improved, but manufacturing precision requirements increase due to dimensional stack-up issues
Solution Approach 1:
The control element is integrated directly into the clutch assembly rather than being a separate external component. This merging eliminates the need for additional fastening operations and reduces the number of interfaces between components, thereby reducing dimensional stack-up issues and manufacturing precision requirements while maintaining the adaptability of multiple clutch operating modes.
Solution Approach 2:
The integrated control element serves multiple functions: it acts as both the control mechanism for selecting clutch modes and as a structural component of the clutch assembly itself. This multi-functionality reduces the number of separate parts that need to be manufactured and assembled, thereby reducing cumulative tolerance requirements while maintaining full adaptability of the clutch system.
3Ease of operation
If control element and activator are positioned far apart, then ease of operation is improved, but device complexity increases due to additional linkage mechanisms
Solution Approach 1:
The control element is positioned asymmetrically close to the activator, breaking the symmetry of traditional designs. This asymmetric placement allows the control element to directly engage the activator with minimal linkage, reducing mechanical complexity while maintaining ease of operation through optimized spatial arrangement rather than relying on long symmetric linkages.
Solution Approach 2:
The complex linkage mechanism is extracted and replaced by a direct mechanical connection between the control element and activator. By removing the intermediate linkage components, the design achieves ease of operation through direct actuation while significantly reducing device complexity. The control element is positioned to allow direct engagement with the activator without requiring additional mechanical intermediaries.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables reliable and efficient bi-directional control of DC motors within vehicular environments by maintaining actuator functionality during system failures, reducing manufacturing complexity and costs, and enhancing clutch position sensing accuracy without mechanical wear.
Implementation Method 1
A failsafe power circuit to controllably store electrical power and apply the stored electrical power based on the failsafe position command signal
Implementation Method 2
a boost circuit to increase the voltage from the vehicle electrical system to charge the storage capacitor
Implementation Method 3
a buck circuit to decrease the voltage from the storage capacitor to supply an appropriate voltage to the electromechanical actuator
Implementation Method 4
supply DC power of a desired polarity to the electromechanical actuator
Data Source
AI summary
An actuator controller to controllably supply DC power to a bi-directional electromechanical actuator is provided. The controller includes a first circuit to receive power and direction command signals from a remote electronic control unit through a vehicle-based bus. Control logic is operative to determine a vehicle system failure and to generate a failsafe position command signal in the event of the failure. A failsafe power circuit controllably stores electrical power and supplies the stored electrical power based on the failsafe position command signal. A power switching and supply circuit supplies DC power of a desired polarity to the electromechanical actuator in response to the power and direction command signals in the absence of the failure and supplies the stored electrical power to the electromechanical actuator in the event of the failure.