System and method for servo control of nonlinear electromagnetic actuators

• US 6,208,497 B1
• Filed: 06/26/1997
• Issued: 03/27/2001
• Est. Priority Date: 06/26/1997
• Status: Expired due to Fees

• Current Assignee: Crystal Investments Incorporated
• Original Assignee: Venture Scientifics LLC
• Inventors: Bergstrom, Gary E., Seale, Joseph B.
• Primary Examiner(s): FLEMING, FRITZ M
• Application Number:
  US08/882,945
• Time in Patent Office: 1,370 Days
• Field of Search: 361/152, 361/154, 361/160
• US Class Current: 361/160
• CPC Class Codes: B60L 13/03 Electric propulsion by linear motors
• CPC Class Codes: B60L 15/005 for control of propulsion for vehicles propelled by linear motors
• CPC Class Codes: F01L 2009/2105 comprising two or more coils
• CPC Class Codes: F01L 2009/4086 Soft landing, e.g. applying braking current; Levitation of armature close to core surface
• CPC Class Codes: F01L 9/20 by electric means
• CPC Class Codes: F02D 13/0253 Fully variable control of valve lift and timing using camless actuation systems such as hydraulic, pneumatic or electromagnetic actuators, e.g. solenoid valves
• CPC Class Codes: F02D 2041/001 for engines with variable valve actuation
• CPC Class Codes: F02D 2041/1419 the control loops being cascaded, i.e. being placed in series or nested
• CPC Class Codes: F02D 41/1401 characterised by the control or regulation method F02D41/1473, F02D41/1477 take precedence
• CPC Class Codes: G01R 31/72 Testing of electric windings testing of transformers G01R31/62
• CPC Class Codes: H01F 7/1607 Armatures entering the winding
• CPC Class Codes: H02K 41/03 Synchronous motors; Motors moving step by step; Reluctance motors H02K41/035 takes precedence
• CPC Class Codes: H02N 15/00 Holding or levitation devices using magnetic attraction or repulsion, not otherwise provided for electric or magnetic devices for holding work on machine tools B23Q3/15 ; monorail vehicle propulsion or suspension B60L13/00; sliding or levitation devices for railway systems B61B13/08; material handling devices associated with conveyors incorporating devices with electrostatic or magnetic grippers B65G47/92; separating thin or filamentary articles from piles using magnetic force B65H3/16; delivering thin or filamentary articles from magnetic holders by air blast or suction B65H29/24; bearings using magnetic or electric supporting means F16C32/04; relieving bearing loads using magnetic means F16C39/06; magnets H01F7/00; dynamo-electric clutches or brakes H02K49/00 ; electric furnaces with simultaneous levitation and heating H05B6/32
• CPC Class Codes: H02P 25/032 Reciprocating, oscillating or vibrating motors

Abstract

Servo control using ferromagnetic core material and electrical windings is based on monitoring of winding currents and voltages and inference of: magnetic flux, a force indication; and magnetic gap, a position indication. Third order nonlinear servo control is split into nested control loops: a fast nonlinear first-order inner loop causing flux to track a target by varying a voltage output; and a slower almost linear second-order outer loop causing magnetic gap to track a target by controlling the flux target of the inner loop. The inner loop uses efficient switching regulation, preferably based on controlled feedback instabilities, to control voltage output. The outer loop achieves damping and accurate convergence using proportional, time-integral, and time-derivative gain terms. The time-integral feedback may be based on measured and target solenoid drive currents, adjusting the magnetic gap for force balance at the target current. Incorporation of permanent magnet material permits the target current to be zero, achieving levitation with low power, including for a monorail deriving propulsion from the levitation magnets. Linear magnetic approximations lead to the simplest controller, but nonlinear analog computation in the log domain yields a better controller with relatively few parts. When servo controlled solenoids provide actuation of a pump piston and valves, electronic LC resonance measurements determine liquid volume and gas bubble volume.

Claims

1. A system for controlling an electromagnetic solenoid including an armature and one or more windings, the system comprising:

a. measurement means couplable to said solenoid for obtaining a position measurement of said armature;

b. means for setting a target flux associated with said solenoid as a function of said measurement; and

c. means for maintaining a solenoid magnetic flux associated with operation of said solenoid near said target, said means including a circuit arrangement which detects an oscillatory slope of a current supplied to the one or more windings, which develops a ratio based on the amount of current being supplied to the one or more windings and the oscillatory slope, and which controls the amount of current with respect to the ratio.

2. The system of claim 1, wherein said means for maintaining said solenoid magnetic flux includes amplifier means for controlling an electric current in at least one of said one or more windings.

3. The system of claim 2, wherein said means for obtaining said position measurement includes means for inferring an approximate ratio of said electric current to said solenoid magnetic flux.

4. The system of claim 3, wherein said approximate ratio is based on a sum of a constant plus a first linear term relating to said electric current plus a second linear term relating to said solenoid magnetic flux.

5. The system of claim 3, wherein said approximate ratio is based on a sum of a constant plus a first linear term relating to said electric current.

6. The system of claim 2 wherein said amplifier means includes a switching amplifier coupled to at least one of said one or more windings.

7. The system of claim 6, wherein said switching amplifier includes a voltage-switching output stage and a comparator input stage, said comparator input stage responding to an error difference between said solenoid magnetic flux and said target to produce an oscillation of variable duty cycle, said variable duty cycle causing said error difference to cross frequently through zero.

8. The system of claim 1, wherein said means for setting said target includes means for determining a magnetic force acting on said armature.

9. The system of claim 3, wherein said means for determining said magnetic force is part of servo means for controlling a position of said armature.

10. The system of claim 8, further comprising derivative control means, responsive to a rate of change in said position measurement, to generate a damping variation in said magnetic force.

11. The system of claim 8, further comprising integral control means, responsive to a persistent error in said position measurement, to generate an accumulating corrective variation in said magnetic force.

12. The system of claim 1, further comprising:

a. means for measuring from at least one of said one or more windings an induced voltage indicative of a time derivative of said solenoid magnetic flux;

b. means for measuring net variations in said solenoid magnetic flux by way of time integration of said induced voltage; and

,

c. means for ensuring that said net variations in said solenoid magnetic flux substantially match said target.

13. The system of claim 12, further comprising:

a. means for determining time-integral measures of said current through said one or more windings;

b. means for determining sums of said time integral measures and said net variations; and

c. means for ensuring that said sums substantially match said target.

14. The system of claim 1, wherein said means for determining said measurement of said position includes a sensor separable from said solenoid.

15. The system of claim 14, wherein said sensor includes a hall-effect sensor.

16. The system of claim 1, wherein said means for maintaining said solenoid magnetic flux includes a hall-effect sensor.

41. The method as claimed in claim 4, wherein said initial position is determined from a ratio of a current through said drive coil and said magnetic flux measured by said sense coil.

42. The method as claimed in claim 41 further comprising the step of introducing a plurality of pre-defined threshold drive pulses based upon measured characteristics of said solenoid so as to define variable armature travel conditions.

17. A system for controlling an electromagnetic solenoid including an armature and one or more windings, the system comprising:

a. means for detecting an oscillatory slope of an electric current in at least one of said one or more windings; and

b. control means, responsive to said oscillatory slope and to a ratio of the current divided by the oscillatory slope, for controlling the electric current and for said ratio to vary as a function of the oscillatory slope.

18. The system of claim 17 wherein said control means comprises amplifier means for controlling the electric current in at least one of said one or more windings.

19. The system of claim 17, wherein said control means includes means responsive to a transfer function of said oscillatory slope, wherein the transfer function includes at least one of:

a proportional term, a time-integral term, and a band-limited derivative term.

20. The system of claim 17, wherein said control means includes means for causing the square of said ratio to vary in proportion to a transfer function of said oscillatory slope.

21. The system of claim 17 further comprising:

a. means for generating a difference of weighted sums of logarithms of the current, the magnetic flux, the oscillatory slope, and a bias signal of said control means; and

b. means for controlling the current in response to the signal difference varying as a function of the weighted sums of the logarithms.

22. A solenoid having a core of a material which minimizes core loss at a predetermined frequency comprising:

a. a drive coil;

b. an armature capable of movement within said drive coil;

c. a yoke coupled to said drive coil, wherein said yoke is positioned in relation to said armature such that there is at least one air gap between said yoke and said armature; and

d. control means including a drive coil controller coupled to said drive coil, wherein said control means regulates movement of said armature within said drive coil based upon measurements of current and an oscillatory characteristic of the current from said drive coil.

23. The solenoid as claimed in claim 22, wherein said control means includes means for measuring a position of said armature and delivering to said drive coil controller said armature position measurement.

24. The solenoid as claimed in claim 22, wherein said control means includes means for measuring a magnetic flux of said drive coil and deriving from said magnetic flux a position measurement of said armature for delivery to said drive coil controller.

25. The solenoid as claimed in claim 22, further comprising a sense coil proximate to said drive coil, wherein said sense coil is used to independently determine said position measurement of said armature.

26. The solenoid as claimed in claim 25, wherein said control means includes a voltage-switching amplifier coupled to said drive coil for controlling movement of said armature.

27. The solenoid as claimed in claim 25, wherein said control means includes a first servo control loop means for determination of position of said armature, and a second servo control loop means related to a determination of force for regulating a drive pulse transmitted by said drive coil controller.

28. The solenoid as claimed in claim 25, wherein said first servo control loop means is coupled to said second servo control loop means.

36. The solenoid as claimed in claim 22, wherein said armature and said yoke have a design based on a pot core.

29. A solenoid comprising:

a drive coil;

an armature capable of movement within said drive coil;

a yoke coupled to said drive coil, wherein said yoke is positioned in relation to said armature such that there is at least one air gap between said yoke and said armature;

control means including a drive coil controller coupled to said drive coil, wherein said control means regulates movement of said armature within said drive coil based upon electrical measurements from said drive coil; and

launch control means for computing and initiating drive coil signals for movement of said armature with minimal electrical power consumption.

30. The solenoid as claimed in claim 29, wherein said launch control means further includes a comparator designed to compare a position of said armature with a set of pre-defined armature positions so as to define a termination operation of said drive coil.

31. The solenoid as claimed in claim 30, including means for identifying a starting position of said armature and internal calibration means.

32. The solenoid as claimed in claim 31, wherein said solenoid is a pump actuator and wherein the solenoid is controlled by a circuit which identifies, based on the position of the armature, the content of the fluid being pumped by the pump.

33. The solenoid as claimed in claim 31 further comprising means for delivering a drive pulse to said drive coil sufficient to force near closure of said gap between said armature and said yoke.

34. The solenoid as claimed in claim 33, further comprising means for delivering a secondary drive pulse to said drive coil to force movement of said armature from near closure to complete closure.

35. The solenoid as claimed in claim 34, further comprising means for delivering a holding signal to said drive coil to maintain complete closure of said armature until delivery of a stop-holding signal.

37. A method for controlling the duration of a drive pulse transmitted to a drive coil of a solenoid having an armature and a yoke so as to move said armature to a prescribed position, said method comprising the steps of:

a. supplying a drive pulse to said drive coil for movement of said armature in relation to said yoke;

b. determining a signal sensitive to movement of said armature;

c. defining as a function of time a threshold for said signal sensitive to said movement;

d. comparing said signal with said threshold; and

e. terminating said drive pulse either when said signal substantially corresponds with said threshold, or when a predefined time limit is reached.

38. The method as claimed in claim 37 further comprising the step of coupling a sense coil to said yoke for determining said signal.

39. The method as claimed in claim 38, wherein the step of determining said signal includes the step of measuring a magnetic flux of said solenoid.

40. The method as claimed in claim 39 further comprising the step of determining an initial position of said armature prior to initiating said drive pulse by transmitting a probe pulse to said drive coil and sensing with said sense coil said magnetic flux of said solenoid.

43. The method as claimed in claim 38 further comprising the step of determining a minimum holding current to be supplied to said drive coil so as to maintain said armature in a fixed position.

44. The method as claimed in claim 37, wherein the step of determining said signal includes the step of measuring a current through said drive coil.

45. A solenoid comprising:

a drive coil;

an armature capable of movement within said drive coil;

control means including a drive coil controller coupled to said drive coil, wherein said control means regulates movement of said armature within said drive coil based upon electrical measurements from said drive coil; and

wherein said solenoid is a reciprocating pump actuator which drives the pump, said solenoid further comprising means for identifying pre-loading of said armature through actuation of said drive coil.

46. The solenoid as claimed in claim 45, wherein the pump has a diaphragm which is flexed by a member rigid with the armature and which further comprises an inlet valve and an outlet valve which respectively control the inflow and outflow of fluid into a chamber which is in part formed by the diaphragm.

47. The solenoid as claimed in claim 46, wherein the solenoid is, when energized, arranged to pull the rigid member back away from the diaphragm against the bias of springs which are included in the solenoid and allow the diaphragm to expand in a direction which allows a volume of a variable volume chamber which is in part defined by the diaphragm, to increase.

48. The solenoid as claimed in claim 47, wherein the rigid member is withdrawn faster than the diaphragm expands and the amount of compliance which is sensed in the diaphragm by monitoring displacement characteristics of the rigid member when the rigid member is allowed to re-engage the diaphragm, is used as a parameter for determining the presence and/or amount of gaseous fluid which is entrained in a liquid fluid being pumped by the pump.