Solenoid Plunger Movement Monitoring via Current Profile Analysis
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Solution Overview
Problem
Existing methods for determining the movement profile of a plunger-type armature in solenoids are inefficient and unreliable, particularly when internal mechanical friction increases, leading to prolonged movement sequences and reduced force, and typically require additional sensors or end contacts.
Innovation Solution
A method that measures the current profile over time in an electromagnet solenoid, identifies key points such as the first reversal point, and compares them to a reference to assess changes in movement and friction, generating fault signals without additional sensors or end contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional movement sensors and end contacts are used to monitor armature movement, then measurement reliability improves, but device complexity increases
Solution Approach 1:
The patent extracts the measurement function from separate physical sensors and end contacts, and relocates it to the existing electrical coil by analyzing current profile characteristics. This eliminates the need for additional movement sensors and end contacts while maintaining measurement capability through electrical parameter analysis alone.
Solution Approach 2:
The electrical coil serves dual functions: generating the magnetic field necessary for solenoid operation and simultaneously acting as a sensing element for monitoring armature movement through current profile analysis. This multi-functionality eliminates the need for dedicated measurement components.
2Reliability
If internal mechanical friction increases, then the movement sequence is prolonged and force is reduced, but detecting these changes requires complex additional sensors
Solution Approach 1:
The system continuously monitors the current profile during solenoid operation and uses feedback from current magnitude and reversal point timing to detect changes in mechanical friction. When friction increases causing prolonged movement sequences, the feedback mechanism identifies these changes through deviations in current characteristics without requiring additional sensors.
Solution Approach 2:
The patent replaces mechanical measurement systems (movement sensors, end contacts) with an electrical measurement approach by analyzing current profile characteristics. This substitution detects mechanical friction changes through electrical parameter analysis, eliminating the need for complex mechanical sensing components.
3Productivity
If the solenoid operates with increased mechanical friction, then productivity decreases due to prolonged movement, but early detection is difficult without additional sensors
Solution Approach 1:
The continuous feedback mechanism analyzes current profile characteristics during each operational cycle, detecting timing deviations that indicate prolonged movement due to friction. This enables real-time monitoring of productivity degradation caused by increased mechanical friction.
Solution Approach 2:
The system performs preliminary detection of friction changes by analyzing current profile characteristics before they cause significant productivity loss. By monitoring reversal point timing and current magnitude variations, the system identifies early signs of friction increase that would otherwise go undetected.
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 method provides a more expedient and reliable means to monitor plunger-type armature movement and friction changes, enabling early detection of slowdowns and increased friction losses, and triggering warning messages in medium-voltage switchgear installations.
Implementation Method 1
the solenoid is an electromagnet in which the magnetic field can be generated by means of an electrical coil
Implementation Method 2
a measuring unit is connected to the electrical coil, wherein the current profile with respect to time is measured when the solenoid is operated
Data Source
AI summary
A method and a device determine a movement profile of a solenoid plunger in a solenoid for monitoring a plunger-type armature movement for changes. The solenoid is an electromagnet in which a magnetic field can be generated by an electrical coil and a measuring unit is connected to the electrical coil. The method includes measuring a current profile with respect to time when the solenoid is operated, examining a measured current profile with respect to time for a position of a first reversal point in respect of time after operation of the solenoid and a current intensity, and assigning the position of the first reversal point to a movement end of the plunger-type armature.