Solenoid systems and methods for achieving lower cost
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Solution Overview
Problem
Solenoids in HVAC devices are costly due to the need for multiple designs to accommodate different voltage inputs, leading to increased stock keeping units (SKUs) and material inefficiencies.
Innovation Solution
A solenoid system capable of operating across a wide voltage range (24 VAC to 480 VAC) with feedback and regulation mechanisms, including rectification, voltage-to-frequency conversion, and the use of aluminum conductors, to reduce copper usage and coil sizes, thereby reducing SKUs and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple solenoid designs are used to accommodate different voltage inputs, then voltage compatibility is improved, but device complexity and SKU quantity increase
Solution Approach 1:
The patent implements a universal solenoid design with a rectifier circuit that can accept multiple AC voltage inputs (120V, 240V, 85V) and convert them to a standardized DC output for the coil. This single multi-functional design replaces multiple voltage-specific solenoid models, reducing SKU quantity while maintaining broad voltage compatibility across different regional standards.
Solution Approach 2:
The rectifier circuit serves as an intermediary component between the AC power source and the DC solenoid coil. It mediates the voltage conversion process, allowing the solenoid to interface with various AC voltage standards without requiring multiple coil designs. This intermediary transformation enables universal compatibility while maintaining a single standardized coil specification.
2Reliability
If copper conductors are used in the coil, then electrical conductivity is improved, but material cost and weight increase
Solution Approach 1:
The patent changes the material parameter of the conductor from copper to aluminum. Aluminum provides sufficient electrical conductivity for solenoid operation while significantly reducing both material cost and weight. The rectifier circuit's ability to provide controlled DC output ensures reliable operation with aluminum conductors, compensating for aluminum's slightly lower conductivity compared to copper through optimized current control.
3Force
If high current is provided to the coil, then magnetic field strength is improved, but power consumption increases
Solution Approach 1:
The patent employs pulse-width modulation (PWM) control to provide periodic current pulses to the solenoid coil rather than continuous high current. The rectifier circuit generates high-current pulses during actuation to achieve sufficient magnetic field strength for valve opening, then reduces or eliminates current during the holding phase. This periodic action maintains effective solenoid operation while dramatically reducing average power consumption compared to continuous high-current 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
The system achieves cost savings by minimizing the number of HVAC device models required and optimizing copper wire usage, while maintaining effective control over solenoid operation.
Implementation Method 1
a rectifier coupled to the alternating current input. The rectifier is configured to convert the alternating current input signal to a direct current signal
Implementation Method 2
When current is provided through the coil, a magnetic field generated by the coil causes a movable core or other element to be drawn into the coil or otherwise moved
Data Source
AI summary
An actuator includes a solenoid including a coil and a plunger, a switch circuit coupled to the coil, and a control circuit coupled to the switch circuit. The control circuit is configured to receive a feedback signal representative of a plunger position. The control circuit is also configured to provide power to the solenoid via the switch circuit and reduce power to the solenoid via the switch circuit in response to the feedback signal being representative of the plunger being in a full travel position.