Actuator Lost Motion Detection Using Multiple Position Sensors
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Solution Overview
Problem
Existing systems for controlling internal combustion engine functions, such as turbochargers and valves, face challenges in accurately determining actuator performance and detecting lost motion, which can lead to decreased efficiency and eventual failure due to wear and looseness in components.
Innovation Solution
A method utilizing multiple position sensors connected to an electrical drive device and an output element, where a controller calculates the difference between sensor output values to determine present measurable characteristics, including lost motion, and records them for performance monitoring and maintenance prediction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple position sensors are added to the actuator system, then measurement precision of actuator performance is improved, but device complexity increases
Solution Approach 1:
The actuator system is segmented into multiple measurement points using separate position sensors (first position sensor on rotor, second position sensor on output element) to independently measure different aspects of actuator performance. This segmentation enables precise detection of lost motion by comparing readings from multiple sensors rather than relying on a single complex sensor.
Solution Approach 2:
The controller is designed to perform multiple functions: it not only controls the actuator operation but also processes sensor data, calculates lost motion, determines performance characteristics, and generates maintenance alerts. This multi-functionality consolidates what could be separate systems into a single integrated controller, reducing overall system complexity while maintaining high measurement precision.
2Reliability
If continuous monitoring of actuator characteristics is implemented, then reliability of actuator operation is improved, but use of energy increases
Solution Approach 1:
The system implements continuous feedback monitoring where position sensors continuously provide data to the controller, which calculates lost motion and performance characteristics in real-time. This feedback mechanism enables early detection of actuator degradation and triggers maintenance alerts before failure occurs, significantly improving reliability. The energy consumption is minimized by using simple position sensors rather than complex measurement devices and by processing data efficiently in the existing controller.
3Productivity
If lost motion detection capability is added to the actuator, then productivity of maintenance scheduling is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary detection of lost motion and performance degradation trends before actual actuator failure occurs. By continuously monitoring and calculating lost motion, the system identifies deterioration patterns early, enabling proactive maintenance scheduling. This preliminary action prevents unexpected failures and optimizes maintenance timing, improving productivity without requiring complex additional hardware beyond the position sensors and controller processing capabilities.
Data Source
AI summary
A method, using multiple position sensors, for determining a characteristic of the actuator or a system, wherein the characteristic is causing or is indicative of the cause of the change in position of the actuator. One characteristic may be the lost motion of the actuator or system. Lost motion is the lag between the motion of a controlled device and that of an electrical drive device due to yielding or looseness. The lost motion of an actuator may increase as components wear and may eventually degrade the function or cause failure of the actuator and/or system.