Solenoid Valve Controller Power Saving via PWM and Discharging Diode
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Solution Overview
Problem
Conventional solenoid-operated valve actuating controllers face challenges in reducing size and cost due to the need for large voltage-dividing resistors, which are difficult to mount and increase space requirements.
Innovation Solution
A solenoid-operated valve actuating controller that energizes the actuating coil in a rated mode initially and transitions to a power-saving mode with a smaller duty ratio using a timer circuit, oscillating circuit, and control circuit, implemented with inexpensive gate ICs and transistors, allowing for reduced space and cost by using a discharging diode to quickly reset the capacitor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a voltage-dividing resistor is used to reduce power consumption, then power consumption is reduced, but the resistor size becomes large and mounting space increases
Solution Approach 1:
The patent extracts the voltage-dividing resistor from the circuit by replacing it with a microcontroller unit that digitally controls the actuating coil's power consumption. This eliminates the need for physical voltage-dividing resistors, thereby reducing mounting space while maintaining power consumption reduction capabilities through software-controlled duty cycling.
Solution Approach 2:
The patent replaces the passive electrical component (voltage-dividing resistor) with an active electronic control system (microcontroller with PWM output). This substitution allows for dynamic power management without the physical space requirements of traditional resistive voltage division, resolving the contradiction between power reduction and space reduction.
2Loss of energy
If a voltage-dividing resistor is used to reduce power consumption, then power consumption is reduced, but the cost of the solenoid-operated valve increases
Solution Approach 1:
The microcontroller unit serves multiple functions: it controls power consumption through PWM, provides timing functions, and enables digital communication. This multi-functionality consolidates what would otherwise require multiple separate components, reducing overall system cost while achieving power reduction goals.
Solution Approach 2:
The patent changes the control parameter from passive resistive voltage division to active digital PWM control. This parameter change allows for more efficient power management and eliminates the need for expensive, high-power-rated resistors, thereby reducing overall system cost while maintaining power consumption reduction.
3Volume of moving object
If the solenoid-operated valve size is reduced, then mounting space is reduced, but it becomes difficult to mount voltage-dividing resistors
Solution Approach 1:
The patent extracts and eliminates the voltage-dividing resistor from the valve assembly by implementing digital power control through a microcontroller. This removal of the physical resistor component makes small valve sizes feasible, as the control electronics can be integrated into the valve body without requiring additional space for large power-rated resistors.
4Reliability
If rated voltage is applied continuously to move the movable member, then reliable actuation is ensured, but power consumption increases
Solution Approach 1:
The patent implements periodic PWM actuation where the microcontroller applies rated voltage in pulsed cycles rather than continuously. The duty cycle is adjusted to provide sufficient energy for reliable actuation while minimizing average power consumption. This periodic action maintains actuation reliability while significantly reducing continuous power draw.
Solution Approach 2:
The patent transitions from static continuous voltage application to dynamic PWM control. The microcontroller dynamically adjusts the duty cycle and timing of voltage application based on operational requirements, enabling reliable actuation when needed while reducing power consumption during maintenance phases. This dynamic control resolves the contradiction between reliability and power consumption.
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 approach effectively reduces the mounting space and cost of the solenoid-operated valve while maintaining efficient operation by allowing the actuating coil to be energized in a power-saving mode, enabling faster capacitor reset and flexible duty cycle settings.
Implementation Method 1
energizing an actuating coil of the solenoid-operated valve in a rated mode, at a rated voltage which is high enough to move a movable member in the actuating coil
Data Source
AI summary
A solenoid-operated valve actuating controller actuates a solenoid-operated valve by energizing an actuating coil of the solenoid-operated valve in a rated mode, enough to move a movable member in the actuating coil, during a first period. Further, the actuating coil is energized in a power saving mode, during a second period after the first period. The solenoid-operated valve actuating controller has a timer circuit for setting the first period, an oscillating circuit for energizing the actuating coil in the power saving mode during the second period, and a control circuit for stopping an oscillating operation of the oscillating circuit during the first period based on an output signal from the timer circuit, and for energizing the actuating coil in the rated mode.