Electromagnetic Actuator Current Regulation via Winding Topology
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Solution Overview
Problem
Electromagnetic actuators face challenges in optimizing energy efficiency and operating voltage range, with existing solutions either compromising on electrical consumption or voltage range, and lacking effective current regulation and decoupling between voltage and current control.
Innovation Solution
An electromagnetic actuator with control means that regulate current and voltage through PWM, switching windings between series and parallel modes to manage inrush and holding phases, using identical windings with adjustable resistance to optimize energy efficiency and voltage range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pulsed currents are used to control the actuator, then the actuator can operate with simple control circuitry, but current regulation cannot be achieved and the current is directly linked to voltage without decoupling
Solution Approach 1:
The patent implements a feedback control system using a current sensor to detect the actual current flowing through the coil and a regulator to compare it with a reference voltage. This closed-loop feedback mechanism enables precise current regulation independent of voltage variations, resolving the contradiction between simple control and precise regulation.
Solution Approach 2:
The patent introduces an intermediary regulation circuit between the voltage source and the coil. This intermediary component (regulator with operational amplifier and transistors) decouples the direct link between voltage and current, allowing independent control of current while maintaining compatibility with simple voltage supply sources.
2Power
If the coil resistance increases with temperature, then the actuator can operate at higher powers, but the current regulation becomes unstable and energy efficiency decreases
Solution Approach 1:
The feedback control system continuously monitors the actual current and adjusts the voltage applied to the coil to maintain the desired current level despite temperature-induced resistance changes. This ensures stable operation and optimal energy efficiency across varying power levels and temperatures.
Solution Approach 2:
The patent compensates for temperature effects by dynamically adjusting the control parameters through the feedback mechanism. As temperature and resistance change, the regulator automatically modifies the voltage output to maintain constant current, effectively adapting to parameter changes without sacrificing energy efficiency.
3Adaptability or versatility
If voltage is increased to extend the operating voltage range, then the actuator can operate in more conditions, but current regulation becomes more difficult and energy consumption increases
Solution Approach 1:
The regulation circuit acts as an intermediary that decouples the relationship between supply voltage and coil current. This allows the actuator to accept a wide range of supply voltages while the regulator maintains optimal current levels, preventing excessive energy consumption even when high voltages are applied.
Solution Approach 2:
The patent enables adaptation to different voltage conditions by dynamically adjusting the control parameters through the feedback mechanism. The regulator modifies its output characteristics based on the input voltage level, maintaining efficient operation across the entire voltage range without requiring separate optimization for each voltage level.
4Use of energy by moving object
If separate windings are used for inrush and holding phases, then energy efficiency is improved, but the device complexity and number of components increases
Solution Approach 1:
The patent combines the inrush and holding functions into a single coil winding, eliminating the need for separate windings. The feedback control system achieves phase-specific current profiles using one winding controlled by a regulator that adjusts current based on the operational phase, reducing component count while maintaining energy efficiency.
Solution Approach 2:
The single coil winding is designed to perform multiple functions - serving as both the inrush winding and the holding winding. The feedback control system provides universal control capability, adapting the current characteristics to match the requirements of different operational phases, thereby eliminating the need for dedicated separate windings.
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 achieves stable current regulation independent of voltage and temperature, enabling efficient operation across a wide voltage range with reduced energy consumption and improved handling of voltage variations.
Implementation Method 1
controlling the switching means for placing said at least two windings in parallel mode to generate a first inrush magnetic flux to close the actuator
Implementation Method 2
a magnetic circuit formed by a ferromagnetic yoke extending along a longitudinal axis, and a mobile ferromagnetic core mounted to slide axially
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The actuator has recall and maintaining units (21, 23B), an electrical current regulation unit (22) and a control subunit (24) for controlling voltage provided to windings (L1, L2) during actuator closing operation, and for controlling a winding switching unit (10) to place the windings in parallel mode to generate recall magnetic flow to close the actuator. The units and the subunit control current provided to the windings during maintenance operations of the actuator in close position, and control the unit (10) to place the windings in serial mode to generate maintenance magnetic flow. The windings are cylindrical and aligned along same longitudinal axis.