Actuator Control Power Buffering for Fast Safe Switch-Off
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Solution Overview
Problem
Existing control devices for electrically operated actuators do not adequately address energy management and system behavior during power or energy failures, leading to slow and unreliable switch-off behavior, especially in safety-critical applications.
Innovation Solution
A control device with integrated energy conditioning and management, featuring a microcontroller for generating actuation signals, energy storage for buffering power, and a circuit arrangement for conditioning, rectifying, and converting grid voltage into a stable DC voltage independent of the grid voltage level, enabling safe and rapid transfer of actuators to a safe state during energy failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If energy dissipation is achieved only via heat or power loss, then the actuator system is simple, but the switching behavior in the event of a fault is too slow
Solution Approach 1:
The patent introduces an intermediary energy storage element (capacitor) between the power source and the actuator. This capacitor actively stores electrical energy and releases it rapidly during fault conditions, enabling fast demagnetization of the actuator without relying solely on passive heat dissipation. The intermediary component bridges the gap between available power and immediate energy requirements for safe switching.
2Reliability
If a buffer store for intermediate circuit DC voltage is added to maintain voltage during energy failure, then the reliability of safe switch-off is improved, but the device complexity increases
Solution Approach 1:
The patent merges the energy storage function with the existing intermediate circuit DC voltage regulation system. The buffer store (capacitor) is integrated into the power conditioning circuitry, combining voltage stabilization during normal operation with energy supply during faults. This consolidation achieves reliable safe switch-off while minimizing additional complexity by utilizing existing circuit nodes and components.
3Adaptability or versatility
If the level of intermediate circuit DC voltage is made independent of grid voltage, then the adaptability to different grid conditions is improved, but the circuit arrangement complexity increases
Solution Approach 1:
The patent employs parameter changes in the voltage regulation process, where the circuit arrangement dynamically adjusts the intermediate circuit DC voltage level based on grid conditions. Through controlled rectification and voltage regulation, the system transforms variable grid voltage into a stable intermediate DC voltage, enabling the actuator to operate independently of grid voltage fluctuations without requiring complex external voltage conversion systems.
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 ensures reliable and rapid actuator control, decouples feed-in voltage from actuator supply voltage, prevents incorrect actuation due to varying grid voltages, and allows for safe and dynamic transfer of safety components to their safe state, even in the event of energy failures.
Implementation Method 1
a circuit arrangement for the conditioning, rectification and conversion of the grid voltage into a first intermediate circuit DC voltage
Implementation Method 2
conversion of the grid voltage into a first intermediate circuit DC voltage, wherein a level of the first intermediate circuit DC voltage is independent of a level of the (external) grid voltage
Implementation Method 3
at least one electrical buffer store for the first intermediate circuit DC voltage for buffering a power necessary for maintaining at least one further voltage
Implementation Method 4
buffering a power necessary for maintaining at least one further voltage, derived from the first intermediate circuit DC voltage, for supplying power to the controller unit in the event of failure of the external electrical energy supply
Data Source
AI summary
A control device with integrated energy conditioning and energy management for actuating an electrically operated and/or controlled actuator, including: a controller for generating an actuation signal for the actuator; a connection for connecting the control device to an external electrical energy supply that provides a grid voltage; a circuit arrangement for the conditioning, rectification and conversion of the grid voltage into a first intermediate circuit DC voltage, a level of which is independent of a level of the grid voltage; at least one electrical buffer store for the first intermediate circuit DC voltage for buffering a power necessary for maintaining a further voltage, derived from the first intermediate circuit DC voltage, for supplying power to the controller unit in the event of failure of the external electrical energy supply and for transferring the actuator to a safe state, for example upon failure of the external electrical energy supply.