Solenoid Coil Voltage Control for Directional Valve Power Reduction
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Solution Overview
Problem
Current subsea hydrocarbon production control systems waste significant electrical power due to excessive power supply to directional control valves, leading to inefficiency and increased thermal stress.
Innovation Solution
Implementing a method to dynamically control the voltage of a solenoid coil using pulse width modulation, detecting current perturbations to determine the minimum 'hold-in' current required for operation, and adjusting the voltage accordingly to minimize power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excessive power is supplied to directional control valves to ensure reliable operation, then reliability is improved, but power consumption increases
Solution Approach 1:
The patent applies dynamics by transitioning from static full-power supply to dynamic power adjustment. The system continuously monitors coil current and adjusts the power supply voltage in real-time based on actual solenoid operation needs, using PWM control to vary voltage dynamically while maintaining reliable valve operation at lower average power consumption
Solution Approach 2:
The patent implements feedback by measuring the actual current drawn by the solenoid coil and using this information to adjust the power supply voltage. The system monitors current perturbations that indicate armature movement and uses this feedback to determine when to reduce voltage, creating a closed-loop control system that maintains reliability while optimizing power consumption
2Reliability
If high voltage is continuously applied to the solenoid coil, then solenoid response reliability is improved, but thermal stress increases
Solution Approach 1:
The patent applies periodic action through PWM (pulse width modulation) control, where voltage is applied in periodic pulses rather than continuously. The system switches voltage on and off at high frequency, providing full voltage during needed periods for reliable response while allowing cooling during off periods, thereby reducing overall thermal stress on the solenoid coil
Solution Approach 2:
The system dynamically adjusts voltage levels based on real-time operational needs rather than maintaining constant high voltage. By monitoring armature position and current draw, the system applies high voltage only when needed for actuation and reduces voltage during holding phases, minimizing thermal accumulation while maintaining response reliability
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 approach reduces power consumption by approximately 70% while maintaining reliable operation of directional control valves, addressing the inefficiency and thermal stress issues in existing systems.
Implementation Method 1
energizing a coil of a solenoid of a directional control valve
Implementation Method 2
detecting a current in the coil at which the armature of the solenoid moves between the first position and the second position comprises detecting a perturbation in the current through the coil due to a change in the inductance of the coil
Data Source
AI summary
A method of energizing a coil of a solenoid of a directional control valve, wherein an armature of the solenoid moves between a first position in which the solenoid is operating and a second position in which the solenoid is not operating, the method comprising energizing the coil with a voltage, controlling the voltage, detecting a current in the coil at which the armature of the solenoid moves between the first position and the second position, and using the current at which the armature of the solenoid moves between the first position and the second position increased by a margin as an operating current for energizing the coil of the solenoid.