Solenoid Force Estimation via Voltage and Current Signals
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Solution Overview
Problem
It is challenging to predict and monitor the air gap between the stator and armature in solenoids used in all-wheel drive couplings, making it difficult to determine the required input for desired output forces.
Innovation Solution
A method is developed to estimate the force output and temperature of a solenoid coil by measuring current and voltage values, using electrical parameters to calculate magnetic force and inductance, allowing for adjustment of the duty cycle to achieve desired forces without direct measurement of the air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of air gap is implemented, then measurement precision of air gap would be improved, but device complexity and cost would increase
Solution Approach 1:
The patent uses electrical parameters (current, voltage, inductance) as intermediary measurements to indirectly determine air gap conditions. Instead of directly measuring the physical air gap distance, the system measures electrical characteristics that change with air gap variations, providing accurate air gap information without complex mechanical measurement devices.
Solution Approach 2:
The patent replaces mechanical air gap measurement systems with electrical measurement systems. By measuring inductance, current, and voltage changes in the solenoid coil, the system substitutes complex mechanical sensors and measurement apparatus with simpler electrical measurements that correlate to air gap conditions.
2Device complexity
If electrical parameter measurement method is used, then device complexity is reduced, but direct air gap measurement capability is lost
Solution Approach 1:
The patent establishes electrical parameters as intermediary indicators that reflect air gap conditions. By measuring inductance, current, and voltage which are influenced by air gap changes, the system obtains accurate air gap information indirectly through these electrical mediators without needing direct mechanical measurement.
Solution Approach 2:
The patent exploits changes in electrical parameters (inductance, current, voltage) that occur with air gap variations. By monitoring how these electrical parameters change as the air gap changes, the system derives accurate air gap measurement information from electrical measurements rather than direct physical measurement.
3Manufacturing precision
If solenoid force control is improved, then force output precision is enhanced, but system complexity increases
Solution Approach 1:
The patent implements feedback control by continuously measuring electrical parameters (current, voltage, inductance) and using this information to adjust the drive signal to the solenoid. The controller monitors the actual electrical state and modifies the input signal to achieve the desired force output, creating a closed-loop control system that improves force precision without requiring complex mechanical feedback mechanisms.
Solution Approach 2:
The patent replaces complex mechanical force measurement and control systems with electrical-based control. By using electrical parameter measurements and electrical signal adjustment, the system achieves precise force control without mechanical sensors, linkages, or adjustment mechanisms.
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 accurate estimation and control of magnetic force output, allowing for predictable and adjustable force application in solenoid systems, reducing the need for direct air gap measurement and improving system performance.
Implementation Method 1
A solenoid is a coil of wire that provides a magnetic force when a current is passed through it. A solenoid can create controlled magnetic fields
Implementation Method 2
solenoids are often used as electromagnets to generate linear forces
Data Source
AI summary
A method of estimating force output of a solenoid assembly including a solenoid coil and a corresponding armature upon which the solenoid coil exerts a magnetic solenoid force is provided. The method includes a step of measuring a plurality of data points of current being drawn by the solenoid coil resulting in a plurality of measured current values, a step of measuring a plurality of data points of voltage being supplied to the solenoid coil resulting in a plurality of measured voltage values, and a step of estimating the magnetic solenoid force exerted upon the corresponding armature based on the pluralities of measured voltage and current values, resulting in an estimated force value.