Solenoid Controller Arc Suppression Circuit

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Solution Overview

Problem

Electrical arcing and contact welding issues in lift gate solenoids due to reverse self-induced voltage and voltage drops, leading to increased resistance and temperature, causing the solenoid contacts to remain in a closed position and preventing proper operation.

Innovation Solution

A solenoid controller with an arc suppression circuit, power assist circuit, and time delay circuit to mitigate reverse self-induced voltage, regulate solenoid coil voltage above dropout voltage, and prioritize power to hydraulic solenoid valves, respectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the solenoid contacts are used to switch the electrical motor ON/OFF, then the electrical motor can be controlled, but electrical arcing occurs between the contacts due to reverse self-induced voltage from the motor coil

Engineering Contradiction:

Improvemotor controlVSAvoidelectrical arcing

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A suppression circuit is introduced as an intermediary component between the motor coil and the solenoid contacts. This circuit provides a controlled path for the reverse self-induced voltage from the motor coil, preventing it from causing electrical arcing at the contacts while still allowing the contacts to perform their switching function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The suppression circuit converts the harmful reverse self-induced voltage into a beneficial controlled current path. Instead of allowing the voltage to cause arcing and contact damage, the circuit directs this energy through a resistive path that dissipates it safely, transforming a harmful effect into a protected operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Duration of action of stationary object

If metal erodes on the solenoid contacts due to repeated arcing, then the resistance through the contacts increases, but this leads to temperature increase and eventual welding of the contacts

Engineering Contradiction:

Improvecontact lifespanVSAvoidcontact temperature

Core Design Contradiction:

Duration of action of stationary objectVSTemperature

Solution Approach 1:

The suppression circuit acts as a mediator that protects the contacts from the harmful effects of arcing. By providing an alternative path for the reverse voltage, it prevents metal erosion and the subsequent chain reaction of increased resistance and temperature that would lead to contact welding.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If voltage drops occur in the solenoid coil, then the solenoid may drop out of the closed position, but this prevents proper operation of the lift gate system

Engineering Contradiction:

Improvesolenoid position stabilityVSAvoidlift gate operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The power assist circuit monitors and adjusts the voltage parameter delivered to the solenoid coil. When voltage drops are detected, the circuit compensates by providing additional power, maintaining the voltage above the dropout threshold and ensuring the solenoid remains in the closed position for proper system operation.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If power is delivered to the starter solenoid coil and motor coil simultaneously, then the voltage drop affects both components, but prioritizing power to hydraulic solenoid valves is needed

Engineering Contradiction:

Improvehydraulic valve operationVSAvoidpower distribution control

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The time delay circuit performs preliminary action by controlling the timing of power delivery to different components. It delays power to the starter solenoid coil until after the hydraulic solenoid valves have received adequate power, ensuring critical hydraulic functions are established first before motor operation begins.

Inventive Principle:

Principle #10Preliminary action

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

Effectively suppresses electrical arcing, maintains stable solenoid contact operation, and ensures proper power delivery to hydraulic solenoid valves, preventing contact welding and ensuring reliable lift gate operation.

Implementation Method 1

a starter solenoid coil for moving one or more electrical contacts from a first open position to a second closed position to switch an electrical motor ON/OFF

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The interruption occurs when the lift operation is stopped by the operator, wherein a reverse self-induced voltage is generated from the pump motor coil in the starter solenoid contacts

Methodology Applied

Scientific EffectReverse self-induced voltage: Electromagnetic Induction

Data Source

PatentUS9852862B2Solenoid operated circuit

Publication Date: 2017.12.26 MAXON IND INC

AI summary

A solenoid operated circuit comprises a solenoid switch having a solenoid coil for moving one or more electrical contacts from a first position to a second position to switch an electrical motor ON/OFF, and a solenoid controller that includes an arc suppression circuit that mitigates a reverse self-induced voltage from the electrical motor thereby suppressing electrical arcing on switch contacts.