Bus Module Current Sensing for Electromagnetic Actuator Wear Detection
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Solution Overview
Problem
Existing monitoring systems for electromagnetic actuators in machine control systems require significant computing power to evaluate data from current sensors, leading to complex structures and external wiring, which complicates fault detection and maintenance planning.
Innovation Solution
A bus module with a computing unit directly connected to the current sensor, processing output signals within a common module housing, allowing for simplified structure and reduced computing power, enabling real-time evaluation of actuator performance and fault detection without external wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a current sensor is installed in the electrical line to measure operating current, then actuator status information is obtained, but the system requires considerable computing power and complex external cabling
Solution Approach 1:
The patent combines the current sensor, computing unit, and bus module into a single integrated module housing. This merging eliminates external cabling between these components and reduces the overall system complexity while maintaining the capability to measure and evaluate actuator status information.
Solution Approach 2:
The patent creates a separate, self-contained bus module that can be independently installed and configured. This segmentation allows the monitoring functionality to be added without redesigning the entire system, and the module can be positioned close to the actuator to minimize cabling requirements.
2Measurement precision
If an evaluation unit with microprocessor is used to process current sensor data, then actuator status is evaluated, but considerable computing power is required
Solution Approach 1:
The computing unit in the bus module performs only the specific evaluation tasks needed for actuator monitoring (comparing current values, detecting deviations) rather than general-purpose processing. This partial action approach reduces computing power requirements while maintaining sufficient evaluation capability.
Solution Approach 2:
The bus module performs self-evaluation of the actuator status by directly processing current sensor data locally. This distributed intelligence approach eliminates the need for a centralized high-power processing system, as each module independently monitors its own actuator.
3Loss of information
If external cabling is used to connect current sensor to computing unit, then data can be transmitted, but installation complexity increases
Solution Approach 1:
By integrating the current sensor and computing unit within the same module housing, the patent eliminates the need for external cabling between these components. Data transmission occurs through internal connections, dramatically simplifying installation while ensuring reliable data transfer.
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
This solution enables early detection of actuator faults, allowing for proactive maintenance, reducing the risk of system failure by continuously monitoring actuators during operation and providing timely replacement opportunities.
Implementation Method 1
actuators include, for example, switching valves, contactors, actuators, and the like, which have an electromagnetically moved armature
Implementation Method 2
To measure the current flowing in the supply line to an actuator, a current sensor (shunt resistor) must be installed in the electrical line
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a bus module with a control unit (50) for controlling electromagnetic actuators (2) of a machine control (10) via a bus (5), in particular for controlling actuators (2) with an electromagnetically moved armature (21) such as switching valves (20), contactors (30) or the like, wherein the actuator (2) is connected to a power source (9) via an electrical line (3) and the control unit (50), and to a current sensor (4) arranged in the electrical line (3), which is configured to detect the instantaneous operating current (I) of an actuator (2) flowing in the electrical line (3).To detect the wear condition of an actuator (2), the bus module (1) includes a computing unit (40), wherein the current sensor (4) is connected to the computing unit (40), and the computing unit (40) is configured to process the output signal (41) of the current sensor (4), wherein the control unit (50), the computing unit (40) and the current sensor (4) are arranged in a common module housing (8).