Solenoid Valve Coil Monitoring With Adaptive Current Sensing
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Solution Overview
Problem
Existing solenoid valve monitoring systems are not universal, require calibration, and fail to accurately assess switching characteristics and protect against coil short circuits, leading to inefficiencies in identifying malfunctions and potential system-wide failures.
Innovation Solution
A microprocessor-based monitoring device with an adjustable amplifier and analogue-to-digital converter system that measures coil current and voltage, allowing for universal application across various solenoid valves by adjusting gain settings to fit different coil currents, and includes protection against short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple electronic analogue circuit is used to monitor solenoid valve operation, then the device complexity is reduced, but the measurement precision and ability to assess switching characteristics deteriorates
Solution Approach 1:
The patent replaces simple electronic analogue circuitry with a microprocessor-based digital measurement system. The microprocessor analyzes the current waveform characteristics digitally, enabling precise assessment of solenoid valve switching behavior, slider movement depth, and mechanical component operation without requiring complex analogue signal conditioning circuits.
Solution Approach 2:
The patent transforms the monitoring approach by measuring multiple electrical parameters (current magnitude, rise time, fall time, waveform shape) and using digital signal processing to extract mechanical operation characteristics. This parameter-based digital analysis provides superior measurement precision compared to simple voltage comparison methods.
2Device complexity
If a fixed-gain measurement system is used, then the device complexity is reduced, but the adaptability to different solenoid valve types deteriorates
Solution Approach 1:
The patent implements a dynamic measurement system with an adjustable amplifier whose gain can be modified based on the specific solenoid valve being monitored. The microprocessor controls the amplifier gain to optimize the measurement range for different valve types, coil powers, and operating conditions, enabling universal application across diverse solenoid valve configurations.
Solution Approach 2:
The patent creates a universal monitoring device that can adapt to different solenoid valve types through programmable measurement parameters and adjustable amplification. The system can monitor various valve configurations without requiring hardware modifications, achieving multi-functionality through software-controlled adaptability.
3Adaptability or versatility
If the measurement range is increased to cover all possible current values, then the adaptability improves, but the measurement precision for specific current ranges deteriorates
Solution Approach 1:
The patent uses a dynamic amplifier with adjustable gain controlled by the microprocessor. Based on the measured current magnitude and the specific solenoid valve characteristics, the system automatically selects the appropriate gain setting to optimize measurement precision for the current range being monitored, rather than using a fixed wide measurement range.
4Ease of operation
If monitoring is performed without protecting against short circuits, then the ease of operation improves, but the reliability deteriorates
Solution Approach 1:
The patent implements continuous feedback monitoring of the coil current through the measurement system connected to the microprocessor. The microprocessor analyzes the current waveform in real-time and can detect short circuit conditions, enabling protective action while maintaining normal operation during legitimate high-current conditions.
Solution Approach 2:
The patent incorporates protective circuitry that can preemptively respond to short circuit conditions by detecting abnormal current patterns and switching off the power supply before damage occurs. The system distinguishes between legitimate high-current operation and fault conditions using waveform analysis.
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
The solution provides comprehensive monitoring of solenoid valve operation, detecting abnormalities and wear, protecting against short circuits, and ensuring accurate switching assessments without requiring device recalibration for different valve types, thus enhancing diagnostic capabilities and maintenance scheduling.
Implementation Method 1
control of direction of a flow of air enabling the solenoid to open and close is achieved by changing a position of a slider (connected to the solenoid linor or without the linor) by means of an electromagnetic field generated in the solenoid coil
Implementation Method 2
measuring voltage at the measurement resistor
Data Source
AI summary
A device for monitoring the operation of a solenoid valve. This device includes a circuit for powering the coil of a solenoid valve, with terminals designed for connection to the coil, a power supply switching transistor, and a measurement resistor. The device also includes a microprocessor-based measurement system that includes an analogue-to-digital converter with a consumed current measurement channel connected to the measurement resistor and a consumed current amplified measurement channel connected to the consumed current measurement channel via an adjustable amplifier. The system is designed to deactivate the power supply switching transistor when a voltage exceeding a threshold value is detected on the consumed current measurement channel, and control the gain of the adjustable amplifier so that the signal at the input of the consumed current amplified measurement channel is within the measurement range of this channel.