Integrated Solenoid Assembly With Flexible PCB Current Control
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Solution Overview
Problem
Existing solenoid-driven electromechanical devices face challenges in integrating a constant-current controller circuit due to the large and rigid PCBs containing MOSFETs, making retrofitting difficult and costly.
Innovation Solution
A compact, flexible PCB with a GaNFET switch is integrated directly with the solenoid assembly, allowing for a drop-in replacement that includes a switching circuit to provide constant current control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a MOSFET-based constant-current controller circuit is used, then constant current control is achieved, but the PCB size becomes large and rigid, making integration with solenoid assembly difficult
Solution Approach 1:
The patent merges the constant-current controller circuit directly with the solenoid assembly by integrating the circuit board with the solenoid driver housing, eliminating the need for a separate remote PCB mounting location. This combination reduces overall system complexity and facilitates easier integration.
Solution Approach 2:
The patent employs a flexible circuit board instead of a rigid PCB, allowing the circuit to be integrated within the solenoid assembly's compact space. The flexible nature of the circuit board enables it to conform to the available space and simplifies installation and retrofitting processes.
2Reliability
If a remote PCB mounting is used for the controller circuit, then circuit functionality is maintained, but retrofitting existing electromechanical devices becomes difficult and costly
Solution Approach 1:
The controller circuit is merged with the solenoid assembly into a single integrated unit, allowing existing electromechanical devices to be retrofitted by replacing only the solenoid assembly rather than installing a separate remote PCB. This significantly simplifies the retrofitting process and reduces installation complexity.
Solution Approach 2:
The integrated solenoid assembly with built-in constant-current control serves multiple functions: it acts as both the actuator and the controller, making it universally applicable to various electromechanical devices without requiring device-specific custom PCB designs.
3Device complexity
If the PCB is made compact to fit within the solenoid assembly, then integration is simplified, but the MOSFET size and heat dissipation become constraints
Solution Approach 1:
The patent introduces a heat sink as an intermediary component between the MOSFET and the solenoid assembly housing, facilitating efficient heat dissipation from the MOSFET. The heat sink acts as a thermal conductor that transfers heat away from the compact circuit board, enabling small PCB size without compromising thermal management.
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
Enables efficient conversion of standard solenoids to constant-current solenoids, reducing size and complexity, and facilitating easy integration into existing devices for improved power management.
Implementation Method 1
a solenoid driver including a coil and a printed circuit board (PCB) integrated with and made part of the solenoid assembly. The PCB is configured to provide a constant-current to the coil
Implementation Method 2
The switches are sequentially opened and closed as timed events whereby a periodic current to the solenoid becomes constant when a sufficiently large switching frequency is implemented. The controller may be operated as a pulse-width modulated controller.
Implementation Method 3
Solenoids are often used as the driver to operate many types of electromechanical devices
Data Source
AI summary
A constant-current control circuit comprising a switching circuit including a source voltage, and primary and secondary switches is provided. The primary GaNFET switch is connected with a solenoid assembly coil. The secondary switch is connected with the coil which has an inductance. From t0 to ton, the primary GaNFET switch is closed and the secondary switch is open, the source voltage is applied across the coil, and a counter EMF decays until the voltage across the coil equals the source voltage at ton, thereby allowing current to flow through the coil. From ton to T, the primary GaNFET switch is open and the secondary switch is closed, and a positive EMF equal to the source voltage is applied across the coil until the positive EMF decays to zero at T, such that the current continues to flow through the coil without the source voltage being applied across the coil.