Single Coil Actuator with Adaptive Control for Voltage Range Coverage
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Solution Overview
Problem
Conventional coil-based actuators for low and medium voltage applications require multiple variants to cover various operational ranges, leading to high manufacturing and handling costs, lack reliability due to undetectable failures, and are prone to over-voltage, over-current, and temperature issues, resulting in increased power consumption and self-heating.
Innovation Solution
A single coil actuator with a microcontroller and PWM controller for simplified current control, integrated diagnostic functions for coil and electronic circuit integrity checking, and protection against over-voltages, currents, and temperatures, reducing the need for multiple variants and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple electromagnet variants are used to cover all voltage and current operational ranges, then the actuator can operate across broad operational ranges, but the number of variants and manufacturing complexity increases significantly
Solution Approach 1:
The patent applies parameter changes by using a single electromagnet design with adjustable operating parameters. The microcontroller monitors input voltage and temperature, then dynamically adjusts the drive current parameters to maintain optimal operation across different voltage ranges (low voltage below 1kV and medium voltage 1-50 kV) and temperature conditions. This eliminates the need for multiple electromagnet variants while covering broad operational ranges.
Solution Approach 2:
The patent implements universality by designing a single electromagnet that can universally operate across both low and medium voltage applications. The unified electromagnet design with adaptive control circuitry replaces multiple specialized electromagnet variants, allowing one device to perform multiple voltage and current ranges through electronic parameter adjustment rather than physical redesign.
2Reliability
If conventional coil-based actuators are used without diagnostic functions, then the device complexity is lower, but the reliability decreases due to undetectable failures
Solution Approach 1:
The patent applies feedback by implementing a microcontroller that continuously monitors the coil's electrical characteristics and provides feedback on the electromagnet's operational status. The system measures parameters such as coil resistance and current draw, compares them against expected values, and can detect failures or degradation. This feedback mechanism enables real-time reliability monitoring without requiring complex external diagnostic equipment.
3Adaptability or versatility
If the windings are dimensioned to allow sufficient currents at lowest voltage and highest temperature, then the actuator can operate at extreme conditions, but the power consumption and self-heating increase at highest voltage and lowest temperature
Solution Approach 1:
The patent applies dynamics by making the electromagnet system adaptive rather than static. The microcontroller dynamically adjusts the drive current based on real-time monitoring of input voltage and temperature conditions. At highest voltage and lowest temperature, the system reduces current to minimize power consumption and self-heating, while still maintaining sufficient magnetomotive force. This dynamic parameter adjustment allows extreme condition operation without the penalty of excessive power consumption across all operating points.
4Reliability
If the power MOSFETs and wire sections are dimensioned for the highest current, then the actuator can handle maximum current demands, but the manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by using electronic control to vary the operating current parameters rather than relying solely on fixed hardware sizing. The microcontroller adjusts the drive current based on actual operational needs, allowing the use of slightly smaller, less expensive MOSFETs and wire sections while still maintaining the capability to handle maximum current demands when required. The adaptive control ensures reliable operation across the full current range without requiring components oversized for all 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 solution reduces manufacturing costs, increases reliability by detecting failures and protecting against over-voltages and temperatures, and optimizes current control to minimize power consumption and self-heating, thereby improving the overall performance and adaptability of the actuator.
Implementation Method 1
a single-coil electromagnet (2) whose movable part is interfaceable with a mechanism inside a medium voltage apparatus
Data Source
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AI summary
A single coil actuator for low and medium voltage applications which comprises a single coil electromagnet and a power and control unit operatively connected to said single coil electromagnet. The power and control unit comprises: a first control unit and a second control unit; a power input operatively connected to an input filter and rectifier; a power supply operatively connected to said input filter and rectifier and to said first and second control unit; a power circuit operatively connected to said single coil electromagnet. In the single coil actuator according to the invention, said first control unit is a microcontroller including analogue and digital inputs and outputs, and said second control unit is a PWM controller which controls the current flowing in the single coil electromagnet through said power circuit.