Regenerative Solenoid Drive Circuit for Pull-In and Hold Power Control
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Solution Overview
Problem
Solenoid drive circuits in aerospace applications face inefficiency due to continuous operation in pull-in mode, leading to excessive power waste, and require a hardware solution for efficient switching between pull-in and hold modes to conserve energy.
Innovation Solution
A solenoid drive circuit with a regenerative drive circuit including a diode bridge and capacitors that allows for efficient energy storage and recapture, enabling lower input voltage and current requirements during pull-in and hold modes, and utilizing switches to control current flow through the solenoid coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full rated voltage is applied continuously to energize the solenoid, then the solenoid remains reliably engaged, but power dissipation becomes excessive
Solution Approach 1:
The patent applies periodic action by switching between pull-in mode (full voltage) and hold mode (reduced voltage) to energize the solenoid. The controller periodically applies full rated voltage to ensure reliable engagement, then transitions to reduced voltage to maintain engagement while minimizing power dissipation. This periodic switching resolves the contradiction between maintaining reliability and reducing energy consumption.
Solution Approach 2:
The patent implements dynamics by making the voltage applied to the solenoid variable rather than static. The controller dynamically adjusts the voltage level based on the operational phase: full voltage during pull-in mode for reliable engagement, then reduced voltage during hold mode for energy efficiency. This dynamic voltage adjustment resolves the contradiction between reliability and power dissipation.
2Reliability
If full rated voltage is applied to pull-in the solenoid, then reliable engagement is achieved, but power consumption increases
Solution Approach 1:
The controller applies full rated voltage periodically only during the pull-in phase to ensure reliable engagement, then switches to reduced voltage during the hold phase. This periodic application of full voltage minimizes the duration of high energy consumption while ensuring the solenoid reliably reaches its engaged position, resolving the contradiction between pull-in reliability and energy loss.
Solution Approach 2:
The patent applies preliminary action by providing full voltage to the solenoid only during the initial pull-in phase to achieve engagement, then transitions to reduced voltage for the sustained hold phase. This preliminary high-voltage action ensures reliable engagement is achieved first, then energy consumption is minimized during the extended hold period, resolving the contradiction between pull-in reliability and energy loss.
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 enables more efficient power management by regulating pull-in and hold currents with lower input voltage, reducing overvoltage stress on switches and allowing for energy recapture and storage, thereby improving solenoid drive efficiency and reducing power consumption.
Implementation Method 1
Electromechanical solenoids are used in valves, relays, and contactors. These solenoids consist of an electromagnetically inductive coil wound around a moveable steel or iron slug called the armature or plunger.
Implementation Method 2
a first regenerative drive circuit connected to the first solenoid control circuit and that includes a first regenerative capacitor
Data Source
AI summary
A solenoid drive circuit includes a power source, a first solenoid control circuit connected to the power source, the first solenoid control circuit including a first solenoid coil and a first solenoid control switch that controls a flow current through the first solenoid coil and a first regenerative drive circuit connected to the first solenoid control circuit and that includes a first regenerative capacitor. The first regenerative drive circuit can include a first diode bridge formed of four diodes (D1, D2, D3 and D4) and that has a positive input, a negative input, a positive output and a negative output, wherein the first regenerative capacitor is connected between the positive and negative inputs.