Digital Solenoid I/P Open-Circuit Detection via Coil Current Trip
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Solution Overview
Problem
Existing electro-pneumatic converters in industrial processes face challenges in detecting open circuits in digital solenoid I/P converters using minimal system resources, which is crucial for maintaining process control system reliability.
Innovation Solution
A method and system that apply a fixed voltage to the I/P coil, monitor current levels, and use a digital logic line to trip when the maximum current is reached, allowing for the detection of proper functioning or failure of the I/P coil and drive circuitry by comparing the logic line's state change, thereby minimizing resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional open circuit detection methods are used in digital solenoid I/P converters, then detection capability is improved, but system resource consumption increases
Solution Approach 1:
The system uses its own operational characteristics (current draw during actuation) to perform self-diagnosis for open circuits. The controller monitors whether the I/P coil reaches its normal operating current level during each actuation cycle, using this information to detect open circuits without requiring external diagnostic equipment or additional energy-consuming monitoring systems.
Solution Approach 2:
The controller implements feedback monitoring of the I/P coil current during actuation. By measuring the actual current drawn by the coil and comparing it to expected values, the system gains feedback about the coil's operational status. This feedback mechanism enables open circuit detection while consuming minimal additional resources, as it utilizes the existing control loop infrastructure.
2Measurement precision
If comprehensive monitoring of I/P converter operation is implemented, then diagnostic accuracy is improved, but device complexity increases
Solution Approach 1:
The patent extracts only the essential diagnostic information needed for open circuit detection from the I/P converter's operation. Specifically, it monitors solely whether the coil reaches its normal operating current level during actuation, rather than implementing comprehensive monitoring of all operational parameters. This selective extraction of critical information maintains diagnostic accuracy for open circuits while avoiding the complexity of monitoring every aspect of converter operation.
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 detection of open circuits in digital solenoid I/P converters with minimal resource consumption, ensuring timely diagnosis and potential system adjustments, such as generating alarms or switching to redundant devices, to maintain process control.
Implementation Method 1
a digital solenoid I/P converter includes an I/P coil and drive circuitry, and wherein the digital solenoid I/P converter, when actuated, causes an armature to move from an off-position to an on-position
Implementation Method 2
receiving, from a current sensor, an indication of a current level associated with the I/P coil
Data Source
AI summary
Techniques for diagnosing failures in a digital solenoid I/P converter are provided herein. A controller of the I/P converter may apply a fixed voltage to an I/P coil of the I/P converter, causing an armature to move from an off-position to an on-position in a properly-functioning I/P converter. The controller may receive an indication of whether a digital logic line trip has occurred, indicating that a current for the I/P coil has reached a desired maximum current level. The controller may remove the fixed voltage applied to the I/P coil when the maximum current level is reached or when a threshold period of time has elapsed from the application of the fixed voltage to the I/P coil. The controller may diagnose, based on whether the digital logic line trip occurred prior to removing the fixed voltage, a failure in the I/P converter.