Unified Diagnostics for Storage Device Energized Actuator
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Solution Overview
Problem
Existing actuator systems lack effective diagnostics to distinguish between energy storage device and actuator health issues, leading to inefficient maintenance and potential system failures, particularly in HVAC and similar applications where accurate identification of component failures is crucial.
Innovation Solution
A unified diagnostics system using a microcontroller to measure and analyze voltage across an energy storage device and actuator current, employing techniques such as current-to-voltage conversion and back electromotive force measurement to determine storage device capacitance and actuator health, allowing for accurate identification of compromised components without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If voltage measurement alone is used to monitor energy storage device health, then the monitoring is simple, but it cannot distinguish between capacitor degradation and actuator current consumption issues
Solution Approach 1:
The diagnostics system segments the failure analysis by separately measuring voltage across the energy storage device and current through the actuator. This segmentation allows independent evaluation of capacitor health (via voltage) and actuator health (via current), resolving the inability to distinguish between component failures.
Solution Approach 2:
The microcontroller acts as an intermediary that processes both voltage and current measurements to determine component health. It uses these measurements to calculate capacitance and distinguish whether voltage drop is due to capacitor degradation or increased actuator current consumption.
2Measurement precision
If additional diagnostic components are added to detect service switch status and component health, then diagnostic accuracy improves, but device complexity increases
Solution Approach 1:
The microcontroller is designed to perform multiple functions: it monitors voltage across the energy storage device, measures actuator current, detects service switch status, and determines component health. This multi-functionality eliminates the need for separate dedicated components for each diagnostic function.
Solution Approach 2:
The system uses existing components (microcontroller, voltage measurement circuitry, current measurement capability) to perform diagnostic functions without requiring additional external diagnostic equipment. The microcontroller self-monitors the service switch status and component health using its existing measurement capabilities.
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 optimized field maintenance by accurately distinguishing between storage device and actuator failures, ensuring safe operation and reducing energy inefficiencies by determining the need for maintenance and allowing the system to adapt positions of actuators like flue dampers to maintain functionality.
Implementation Method 1
Capacitors of substantially large capacitance (also known as 'super capacitors') are becoming commercially available. One of their target applications is to store energy when power is available from a power source and use the accumulated energy to drive an actuator
Implementation Method 2
One way may be to measure and analyze the voltage across the energy storage device (e.g., capacitor) prior, during, and after driving the actuator. This voltage may be a measure of the health (e.g., capacity) of the energy storage device.
Implementation Method 3
actuator current is also measured to distinguish the two failure modes. The voltage drop and the actuator current are then combined to calculate the storage device capacitance.
Implementation Method 4
FIG. 7 is a diagram of a graph showing a back electromotive force from a motorized actuator used to determine a magnitude of current to an actuator.
Data Source
AI summary
A system having unified diagnostics where an electrical energy storage device may supply an actuator. Various techniques may be used to determine energy storage capacity and actuator current usage. Measured storage capacity and actuator current may indicate the health of the energy storage device and the actuator, respectively. Also, operation of a service switch for the actuator may be checked relative to its state.