Solenoid Status Determination via Current Monitoring
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Solution Overview
Problem
Current diverter control modules in industrial conveyors do not provide information on the condition of solenoid switches, fail to detect potential failures, and cannot report mechanical failures or obstructions, which can lead to significant damage.
Innovation Solution
A system and method for determining the status of a solenoid switch by measuring parameters such as end of stroke time, end of stroke current, reference time, and instantaneous current, using a sensor and control module to compare these parameters to predetermined thresholds to assess the solenoid's state, including satisfactory, warn, failed, shorted, open, and obstruction states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If current diverter control modules are used to control solenoid switches, then the solenoid switch operation is controlled, but no information is provided regarding the condition of the solenoid switch
Solution Approach 1:
The control module continuously monitors multiple parameters (current, voltage, temperature, timing) from the solenoid switch and compares them against reference values to determine operational status. This feedback mechanism provides real-time information about solenoid condition without requiring additional separate monitoring devices, thus resolving the contradiction between information availability and system complexity.
Solution Approach 2:
The control module performs multiple functions: it controls the solenoid switch operation, monitors its condition, detects failures, and provides diagnostic information. By integrating these functions into a single module rather than separate systems, the patent provides comprehensive solenoid information while maintaining reasonable system complexity.
2Reliability
If no condition monitoring is implemented, then the control system remains simple, but early warning of potential switch failure is not provided
Solution Approach 1:
The control module continuously monitors solenoid parameters and compares them against reference values to detect potential failures before they occur. By performing preliminary detection and warning of abnormal conditions, the system improves reliability without requiring complex post-failure analysis systems.
Solution Approach 2:
The control module uses its existing control functions to also perform monitoring and diagnostics of the solenoid switch. The same hardware and software resources used for control are leveraged to provide condition monitoring, eliminating the need for separate dedicated monitoring equipment and thus improving reliability while minimizing additional complexity.
3Object-affected harmful factors
If mechanical failure or obstruction detection is not implemented, then the detection system remains simple, but significant damage to the conveyor may occur
Solution Approach 1:
The control module monitors multiple parameters including current, voltage, temperature, and timing to detect mechanical failures and obstructions. By continuously comparing these parameters against reference values, the system can identify abnormal conditions that indicate mechanical problems, enabling early intervention to prevent conveyor damage.
Solution Approach 2:
The system detects mechanical failures and obstructions by monitoring changes in electrical parameters (current, voltage, temperature, timing) that occur when the solenoid switch experiences mechanical problems. These parameter changes serve as indicators of mechanical issues, allowing detection without direct mechanical sensors.
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 early detection of solenoid switch failures and obstructions, facilitating maintenance and preventing damage to industrial conveyors by providing real-time condition monitoring and reporting.
Implementation Method 1
A solenoid switch includes an electromagnetically inductive coil, wound around a movable armature. The coil is shaped such that the armature can be moved in and out of the center, altering the coil's inductance and thereby becoming an electromagnet.
Data Source
AI summary
Methods and systems for determining the status of a solenoid. A method includes measuring a plurality of parameters associated with a current conducting through the solenoid. The measured parameters are compared to predetermined reference parameters to determine the status of the solenoid. A system includes a sensor configured to measure a plurality of parameters associated with a current conducting through the solenoid. The system includes a control module configured to receive the measured parameters and operable to compare the measured parameters to predetermined reference parameters to determine the status of the solenoid.