Testing and Condition Monitoring of Electromechanical Solenoids
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1 Testing and Condition Monitoring of Electromechanical Solenoids Dipl.-Ing. Andrey Gadyuchko Steinbeis Ihr Partner bei der Entwicklung und Optimierung mechatronischer Antriebssysteme
2 Content 1. Analogy between medicine and technics 2. Limits of conventional testing of electromechanical solenoids 3. The way from ferromagnetic material to the solenoid 3.1 Material magnetic properties of soft-magnetic materials 3.2 Solenoid interpretation of the magnetising curve Ψ(i,δ) 4. Magnetic measurement and testing in examples Functional testing of magnetic actuators under real conditions On-Site-Troubleshooting Adjustment Nondestructive testing, fault identification Condition Monitoring 5. Application fields 2011 Steinbeis Bewegen durch Innovation 2
3 1. Analogy between medicine and technics 2011 Steinbeis Bewegen durch Innovation 3
4 Analogy between medicine and technics Human Machine 2011 Steinbeis Bewegen durch Innovation 4
5 Analogy between medicine and technics Heart electro-magneto-mechanical actuator Solenoid body Coil Armature Armature pusher Pressure pipe with magnetic shunt 2011 Steinbeis Bewegen durch Innovation 5
6 Analogy between medicine and technics Heart electro-magneto-mechanical actuator Diagnosis Pulse / Blood pressure Electrocardiogram (ECG) (Measurement electrical Field of the Heart) Diagnostics / Testing mechanical / hydraulic characteristics Electro-magneto-mechanogram (Measurement magnetical field of the actuator) ECG wave Ψ(i,δ) magnetical working curve 2011 Steinbeis Bewegen durch Innovation 6
7 Analogy between medicine and technics Heart electro-magneto-mechanical Actuator Advantages Advantages Electrocardiogram (as medical method) painless not invasive every time repeatable operable in any conditions Magnetical One-Coil-Measurement (as test method) sensorless without changing of the magnetic circuit Solenoid acts in the real condition and ist behaviour is monitored Actuator can be tested 1) over influence of different external conditions 2) with different loads 3) being installed in the system 2011 Steinbeis Bewegen durch Innovation 7
8 Analogy between medicine and technics Heart electro-magneto-mechanical Actuator Measuring in static Ψ(i,δ) δ=const - static curve Magnetisation curve of the solenoid with fixed armature ü Information about magnetic circuit Measuring in dynamic Ψ(i,δ) dynamic curve Magnetisation curve of the solenoid with moving armature ü Information about Function 2011 Steinbeis Bewegen durch Innovation 8
9 Testing device MagHyst MagHyst - basis 2011 Steinbeis Bewegen durch Innovation 9
10 MagHyst - family MagHyst - basis 2011 Steinbeis Bewegen durch Innovation 10
11 2. Limits of conventional testing of electromechanical solenoids 2011 Steinbeis Bewegen durch Innovation 11
12 Solenoid electro-magneto-mechanical system Solenoid W q electric energy Coil, Iron circuit magnetic energy Armature Air gap mechanic energy δ electric supply thermal energy Source: E. Kallenbach Elektromagnete 2011 Steinbeis Bewegen durch Innovation 12
13 Mechanical testing F(i,δ) - main curve of the solenoid Solenoid W q electric energy Coil, Iron circuit magnetic energy Armature Air gap mechanic energy δ electric supply thermal energy F = f(i,δ) by i = const F = f(i,δ) by δ = const 2011 Steinbeis Bewegen durch Innovation 13
14 Limits of mechanical testing Solenoid build-in or installed in the system Solenoid W q electric energy Coil, Iron circuit magnetic energy Armature Air gap mechanic energy δ Load electric supply thermal energy Example: - hydraulic valve - braking system etc. F = f(i,δ) by i = const F = f(i,δ) by δ = const 2011 Steinbeis Bewegen durch Innovation 14
15 Complete testing Solenoid W q electric energy Coil, Iron circuit magnetic energy Armature Air gap mechanic energy δ Load electric supply thermal energy Example: - hydraulic valve - braking system etc. Testing of the whole system Flow, preasure = f(i,, x) Braking = f(i,, x) 2011 Steinbeis Bewegen durch Innovation 15
16 Complete testing input electric energy Solenoid as BLACK BOX magnetic energy mechanical energy Valve Load as BLACK BOX output W q EW 1 EW 2 W electric supply elektro-magnetic energy conversion magneto-mechanical energy conversion load thermische Energie Testing of the whole system Flow, preasure = f(i,, x) Braking = f(i,, x) 2011 Steinbeis Bewegen durch Innovation 16
17 INNOVATION: Magnetic testing Solenoid i electric energy Coil, Iron circuit magnetic energy Ψ Armature Air gap mechanic energy δ Load One-Coil- Measurement Ψ(i, δ) working curve u i = dψ/dt = const thermal energy 2011 Steinbeis Bewegen durch Innovation 17
18 Main parameters and functions of electromechanical solenoid voltage Damping action in solenoid current flux linkage reluctance (maxwell) force u i Ψ F m L inductance R w eddy-currents D, F R mechanic damping, friction solenoid force F LOAD (spring) Primary solenoid function: Fi (, ) to produce force over the stroke Testing function: Fi (, ) i=const force-stroke curve Intermediate function: ( i, ) magnetising curve of the solenoid ( i, ) F( i, ) 2011 Steinbeis Bewegen durch Innovation 18
19 3. The way from ferromagnetic material to the solenoid 3.1 Material magnetic properties of soft-magnetic materials 2011 Steinbeis Bewegen durch Innovation 19
20 Magnetic properties of soft-magnetic materials Quasistatic hysteresis curve С45, Vacoflux 50, FeCoV2 Demagnetization of the testing object 2011 Steinbeis Bewegen durch Innovation 20
21 Magnetic properties of soft-magnetic materials Heat treatment (annealing) to improve magnetic properties 11SMn30 annealed, 11SMn30 not annealed Alloying FeCo, FeCoV Steinbeis Bewegen durch Innovation 21
22 Magnetic properties of soft-magnetic materials New curve with minor hysteresis loop Minor hysteresis loop Analysis of magnetisation losses 2011 Steinbeis Bewegen durch Innovation 22
23 Magnetic properties of soft-magnetic materials Eddy-current losses Dynamic remagnetisation: 2, 4, 6, 8, 10 Hz Commutation (normal magnetisation) curve 20 minor hysteresis loops 2011 Steinbeis Bewegen durch Innovation 23
24 Quasistatic Psi(i) measurement with following B(H) calcualation 2011 Steinbeis Bewegen durch Innovation 24
25 Correlation between Psi(i) and B(H) for homogenous field in testing object 2011 Steinbeis Bewegen durch Innovation 25
26 3. The way from ferromagnetic material to the solenoid 3.1 Solenoid interpretation of the magnetising curve Ψ(i,δ) 2011 Steinbeis Bewegen durch Innovation 26
27 Flux, flux linkage, inductance und magnetising curve? Ψ The inductance depends from the geometry and dimensions of the electic system and also from the permeability of the material where the magnetic flux acts. Vs flux linkage Φ Vs flux L H inductance (self-inductance) w w Li i A current δ mm air gap number of windings 2011 Steinbeis Bewegen durch Innovation 27
28 Open magnetic system Conductor loop L сonst 2011 Steinbeis Bewegen durch Innovation 28
29 Open magnetic system Air-core coil w L konst 2011 Steinbeis Bewegen durch Innovation 29
30 Closed magnetic system Current increasing/decreasing Toroidal core Homogeneous Field in Testobjekt B(H) material curve is calculated from the Ψ(i) magnetising curve 2011 Steinbeis Bewegen durch Innovation 30
31 Half-closed magnetic system Ψ(i, δ) δmin magnetising curve Proportional solenoid Armature Armature in endposition minimal air gap magnetic shunt 2011 Steinbeis Bewegen durch Innovation 31
32 Half-closed magnetic system Ψ(i, δ) δmax magnetising curve Proportional solenoid Armature Armature in start position maximal air gap magnetic shunt 2011 Steinbeis Bewegen durch Innovation 32
33 Half-closed magnetic system Ψ(i, δ) working area with hysterisis Proportional solenoid Armature magnetic shunt moving armature Variable air gap 2011 Steinbeis Bewegen durch Innovation 33
34 Solenoids Fingerprint Ψ(i, δ) set of static magnetisation curves by fixed air gap Analysis of magnetic circuit: - hysteresis - eddy currents - remanent magnetism - working stroke Set of curves for rapid solenoid simulation in MatLab-Simulink Fixed armature different air gaps 2011 Steinbeis Bewegen durch Innovation 34
35 Magnetic working curve of the proportional solenoid Ψ(i, δ) magnetic working curve Analysis of the armature start position Dead zone Current increasing Armature in start position maximal air gap 2011 Steinbeis Bewegen durch Innovation 35
36 Magnetic working curve of the proportional solenoid Ψ(i, δ) magnetic working curve Working area Analysis of the movement (switching-on) - opening i A / saturation i B current - overcoming of spring preload and static friction - stroke motion - active region - spring stiffness - end position - stick-slip effect by movement - external influence Current increasing Armature moves to end position variable air gap 2011 Steinbeis Bewegen durch Innovation 36
37 Magnetic working curve of the proportional solenoid Ψ(i, δ) magnetic working curve Analysis of the armature end position - reserve for the load - vibration at endposition - contamination - stick of the armature Current increasing Power reserve Armature to end position minimal air gap 2011 Steinbeis Bewegen durch Innovation 37
38 Magnetic working curve of the proportional solenoid Ψ(i, δ) magnetic working curve Analysis of the friction in the system Current decreasing Reversal range Armature to end position minimal air gap 2011 Steinbeis Bewegen durch Innovation 38
39 Magnetic working curve of the proportional solenoid Ψ(i, δ) magnetic working curve Analysis of the movement (switching-off) Current hysteresis Current decreasing Armature moves to start position variable air gap 2011 Steinbeis Bewegen durch Innovation 39
40 Magnetic and hydraulic working curves of the proportional solenoid valve Ψ(i, δ) magnetic working curve Hydraulic flow-current-curve Working area Dead zone Working stroke Dead zone Saturation Saturation Working stroke Current hysteresis Current hysteresis Reversal range Working area Pull-in current Dropout current Nominal current 2011 Steinbeis Bewegen durch Innovation 40
41 Working cycle (switching-on and switching-off) of the switching solenoid Working cycle Time parameters 2011 Steinbeis Bewegen durch Innovation 41
42 Repeatability of the measurement Control of manufacturing process stability 25 repeated measurements of one solenoid 25 solenoids from one series 2011 Steinbeis Bewegen durch Innovation 42
43 4. Magnetic testing in examples 2011 Steinbeis Bewegen durch Innovation 43
44 Magnetic on-site-troubleshooting Operating point movement while switching on for 3 o.k. injectors J J J 2011 Steinbeis Bewegen durch Innovation 44
45 Magnetic on-site-troubleshooting Operating point movement while switching on for 4 injectors Δ 2 = 13,5% J L J J 2011 Steinbeis Bewegen durch Innovation 45
46 Adjustment Magnetic test and adjustment J J J J 2011 Steinbeis Bewegen durch Innovation 46
47 Adjustment J J J J 2011 Steinbeis Bewegen durch Innovation 47
48 Assembling quality control Solenoid o.k. Proportional solenoid J 2011 Steinbeis Bewegen durch Innovation 48
49 Assembling quality control manufacturing error Dropout delay Proportional solenoid Switching operation Stroke energy L 2011 Steinbeis Bewegen durch Innovation 49
50 Faults detection via magnetic testing four solenoid valves without faults 2011 Steinbeis Bewegen durch Innovation 50
51 Faults detection via magnetic testing short circuit between turnes (10% less windings) 2011 Steinbeis Bewegen durch Innovation 51
52 Faults detection via magnetic testing contamination on the upper side of the armature 2011 Steinbeis Bewegen durch Innovation 52
53 Faults detection via magnetic testing spring defective 2011 Steinbeis Bewegen durch Innovation 53
54 Faults detection via magnetic testing armature geometry and size variation 2011 Steinbeis Bewegen durch Innovation 54
55 Faults detection via magnetic testing excessively press-fitting of the valve 2011 Steinbeis Bewegen durch Innovation 55
56 Faults detection via magnetic testing solenoid with excitation coil for 6V and 12V 2011 Steinbeis Bewegen durch Innovation 56
57 Faults detection via magnetic testing sealing element is damaged 2011 Steinbeis Bewegen durch Innovation 57
58 Faults detection via magnetic testing armature sticks at start position 2011 Steinbeis Bewegen durch Innovation 58
59 Faults detection via magnetic testing armature sticks at end position 2011 Steinbeis Bewegen durch Innovation 59
60 Condition Monitoring de.academic.ru/dic.nsf/dewiki/ Steinbeis Bewegen durch Innovation 60
61 5. Application fields 2011 Steinbeis Bewegen durch Innovation 61
62 Application field R&D Manufacturing User Laboratory Prototype creating of own database for used ferromagnetic materials material choice for simulation analysis of mechanical treatment influences operability test of the prototype under real conditions design optimization Purchase, incoming test of soft-magnetic materials ferromagnetic parts Batch production in-line test assembling quality control adjustment end-of-line test operability test under load adjustment of control electronics on the real actuator behavior hysteresis compensation condition Monitoring BH ( ) () i ( i, ) - material curve - magnetising curve - working curve 2011 Steinbeis Bewegen durch Innovation 62
63 quick + easy + flexible + automated = cost-effective only electric connectors are needed test under real or quite different operating conditions no sensors milliseconds or seconds for each measurement (depending on solenoid inductance) 2011 Steinbeis Bewegen durch Innovation 63
64 MagHyst - references 2011 Steinbeis Bewegen durch Innovation 64
65 Thank you for your attention. Measure what is measurable, and make measurable what is not so" Galileo Galilei Science begins with measurement D.I. Mendelejew... without measurement is today no one ambitious actuator imaginable S. Helduser 2011 Steinbeis Bewegen durch Innovation 65
66 2011 Steinbeis Bewegen durch Innovation 66
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