PWM Servo Clutch Driver for Constant Closure Force
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Solution Overview
Problem
Solenoids used in servo clutches face issues with maintaining closure force under varying temperature and voltage conditions, leading to potential disengagement and increased power consumption, which can result in reliability issues due to heat generation and insulation breakdown.
Innovation Solution
A pulse width modulated servo clutch driver system that includes a voltage source, current sensor, and processor to generate a PWM signal based on voltage and current signals, controlling the solenoid current to maintain a constant level and minimize power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coil resistance is designed to be sufficiently low to maintain closure force under high temperature and low voltage conditions, then closure force reliability is improved, but power consumption increases and heat generation occurs
Solution Approach 1:
The patent implements dynamic control of coil resistance through a switching network that reconfigures the coil connections based on operating conditions. The controller adjusts the effective resistance in real-time, transitioning between different resistance states to optimize both closure force maintenance and power consumption reduction under varying temperature and voltage conditions.
Solution Approach 2:
The patent changes the electrical parameter of coil resistance dynamically by switching between different coil configurations. The controller monitors operating conditions and adjusts the resistance parameter to match required performance levels, thereby maintaining closure force when needed while reducing power consumption when conditions permit.
2Reliability
If coil resistance is designed to be sufficiently low to maintain closure force under worst case conditions, then closure force is maintained, but heat generation increases causing insulation breakdown
Solution Approach 1:
The patent dynamically adjusts coil resistance through switching networks that reconfigure coil connections based on real-time operating conditions. By transitioning between different resistance states, the system maintains adequate closure force under high temperature conditions while minimizing heat generation during normal operation, thereby preventing insulation breakdown.
Solution Approach 2:
The patent converts the potential harmful effect of heat generation into a beneficial control mechanism. By using switching networks to dynamically adjust resistance, the system allows higher current (and thus higher heat) only when absolutely necessary for maintaining closure force, while normally operating at lower heat levels. The controller intelligently manages thermal stress by adjusting resistance to prevent insulation breakdown.
3Reliability
If solenoid is designed for worst case scenario with low resistance, then closure force is maintained under high temperature and low voltage, but power consumption increases under nominal conditions
Solution Approach 1:
The patent implements dynamic resistance control using switching networks that reconfigure the solenoid coil connections based on operating conditions. The controller adjusts the effective resistance in real-time, allowing the system to maintain closure force under adverse high temperature and low voltage conditions while reducing power consumption during nominal operating conditions.
Solution Approach 2:
The patent makes the solenoid system universal by enabling it to function effectively across a wide range of operating conditions through dynamic resistance adjustment. The switching network allows the same solenoid to adapt its resistance to match different operational requirements, whether maintaining closure force under adverse conditions or minimizing power consumption under nominal conditions.
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 system effectively maintains a constant closure force across a wide temperature range and voltage fluctuations, reducing power requirements and minimizing heat generation, thereby enhancing solenoid reliability and performance.
Implementation Method 1
The solenoid includes a coil that is connected to a power supply
Implementation Method 2
under high temperatures, the resistance of coil increases, which reduces the current through coil
Implementation Method 3
a switch, and a processor. The processor is configured to generate a PWM signal for controlling the current through the solenoid
Data Source
AI summary
Disclosed is a system and method for controlling a clutch associated with a solenoid using a pulse width modulated (PWM) signal, which keeps the current through the coil constant over a wide temperature range and fluctuations in line voltage. The system may include a voltage source, a switch (such as a FET), a current sensor, and a processor. The system controls the clutch by sampling the voltage source, sampling the current measured by the current sensor, and computing a duty cycle, which is then used to generate a PWM control signal.