1,478 research outputs found

    A new run-to-run approach for reducing contact bounce in electromagnetic switches

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    Contact bounce is probably the most undesirable phenomenon of electromagnetic switches. It reduces the performance of relays and contactors and is directly related to some of the processes that result in the destruction of the device. In this paper, a complete formulation of the problem is provided and a new strategy inspired by Runto-Run control is presented for reducing contact bounce. The method, which makes use of the repetitive functioning of these systems, is highly versatile and may be applied to different switches under diverse operating conditions. In addition, it is able to deal with changes during the service life of the device, such as plastic deformations or the erosion of the contacts. Several experimental results are included to prove the effectiveness of the method

    Modeling and Control of Reluctance Actuators

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    Los actuadores de reluctancia son dispositivos que se caracterizan por una elevada densidad de fuerza, buena eficiencia, gran tolerancia frente a fallos y un coste reducido. Estas características hacen que estén siendo considerados como una alternativa muy prometedora frente a otro tipo de actuadores electromagnéticos en ciertas aplicaciones que requieren gran velocidad y precisión. Por otro lado, los actuadores de reluctancia también son la solución ideal para algunos dispositivos electromecánicos que requieren unas prestaciones modestas, lo cual es debido principalmente a que son compactos, tienen un bajo coste y consumen relativamente poco. En concreto, los relés electromecánicos y las válvulas de solenoide son dispositivos cuya operación está basada en la fuerza creada por un pequeño actuador de reluctancia.A pesar de sus ventajas, los actuadores de reluctancia son sistemas complejos cuya dinámica es no lineal. Una de sus características más distintivas es que la fuerza magnética que provoca el movimiento es siempre de atracción y, además, depende fuertemente de la posición de la armadura. Básicamente, el comportamiento de esta fuerza es lo que explica que dispositivos como los relés y las electroválvulas sufran fuertes impactos y desgaste cada vez que son activados. Adicionalmente, algunos fenómenos electromagnéticos como la histéresis magnética o las corrientes inducidas hacen que el modelado dinámico de los actuadores de reluctancia sea bastante complejo. El trabajo realizado en esta tesis doctoral está enfocado en estudiar las posibilidades que ofrecen estos actuadores y, en concreto, en analizar el comportamiento dinámico y proponer algoritmos de estimación y control para relés electromecánicos y válvulas de solenoide.El primer objetivo de la investigación es el desarrollo de modelos dinámicos para actuadores de reluctancia, es decir, modelos de orden reducido que puedan ser utilizados para realizar simulaciones transitorias lo más precisas posibles con un bajo coste computacional. Para ello, lo primero que se ha estudiado es el comportamiento electromagnético de estos sistemas. El método de modelado más usado en la tesis es el de los circuitos magnéticos equivalentes (MEC, por sus siglas en inglés). No obstante, también se han realizado algunas simulaciones con modelos de elementos _nitos, en concreto para validar las aproximaciones del método MEC o para calcular la reluctancia del entrehierro. Se han estudiado los principales fenómenos electromagnéticos que aparecen en los actuadores de reluctancia, lo que ha llevado a la obtención de expresiones analíticas para modelar la dispersión de flujo, las corrientes inducidas y la saturación e histéresis magnéticas. Por otra parte, la expresión de la fuerza magnética que produce el movimiento se ha obtenido mediante un balance energético del sistema.El movimiento de la armadura también se ha estudiado en la tesis. Dado que los actuadores de reluctancia tienen generalmente un recorrido físicamente acotado, se han propuesto dos técnicas diferentes que permiten modelar los límites del movimiento y los rebotes de la armadura. Una vez estudiado el movimiento, el modelo mecánico se ha combinado con las ecuaciones electromagnéticas para poder analizar el comportamiento dinámico del actuador en su conjunto. Se han desarrollado cinco modelos dinámicos distintos, desde el más sencillo posible hasta uno que incluye todos los fenómenos electromagnéticos citados con anterioridad, y posteriormente se han comparado teniendo en cuenta su precisión y coste computacional.Las medidas experimentales son fundamentales a la hora de analizar y caracterizar cualquier sistema dinámico. Por ello, otro de los objetivos de la tesis ha sido la evaluación de distintas técnicas de medida que pudieran ayudar a mejorar la comprensión sobre el comportamiento dinámico de los actuadores de reluctancia y, en caso de que fuera posible, formar parte de un bucle de control realimentado. En este sentido, se ha intentado grabar el movimiento de uno de los dispositivos estudiados mediante tres instrumentos ópticos distintos. Los resultados indican que, a pesar de que en ciertas situaciones sí sería posible medir la trayectoria del dispositivo durante su movimiento, ninguno de los instrumentos podría aplicarse en la práctica por su baja flexibilidad y alto coste. Por este motivo, también se ha explorado el uso de otras variables que puedan ser medidas mucho más fácilmente.Otra parte importante de la investigación ha estado centrada en técnicas de estimación. Se han desarrollado dos algoritmos que son capaces de estimar, en tiempo real, el flujo magnético, la resistencia y la inductancia de un actuador dado. Los algoritmos utilizan únicamente medidas de tensión y corriente, lo cual representa una clara ventaja ya que no se necesita utilizar sensores o equipamiento añadido. Las prestaciones de ambos estimadores han sido analizadas mediante simulación y experimentos reales. El problema de estimar la posición de la armadura también se ha abordado en la tesis. En concreto, se ha prestado especial atención en resaltar los efectos que la histéresis magnética produce en la estimación, algo que no había sido estudiado con anterioridad.Finalmente, se han propuesto distintas técnicas de control para actuadores de reluctancia. En concreto, el objetivo principal es lograr que estos sigan un movimiento con aterrizaje suave, es decir, un movimiento que no dé lugar a impactos o rebotes. Como un primer paso, se han estudiado las propiedades básicas de los sistemas de control, es decir, la estabilidad, controlabilidad y observabilidad. Después se ha explorado la técnica de linealización por realimentación como un posible método para diseñar un bucle de control realimentado para la trayectoria de la armadura. Los resultados obtenidos demuestran que el control por realimentación es capaz de controlar el movimiento con gran precisión, siempre y cuando haya disponibles medidas o estimaciones precisas de la posición en tiempo real. Como esta situación es difícil que se dé en la práctica, se ha estudiado el uso de técnicas de control óptimo en bucle abierto para aquellos casos en los que la posición de la armadura no se pueda obtener. En particular, se han obtenido distintas soluciones tiempo óptimo y de energía óptima para un actuador nominal y, posteriormente, se ha analizado su robustez utilizando un método de Montecarlo.Como alternativa a los métodos clásicos, se ha estudiado la aplicabilidad de los métodos Run-to-Run (R2R) en actuadores de relutancia. Estas técnicas están diseñadas específicamente para sistemas que realizan un proceso repetitivo y, por lo tanto, son idóneas para dispositivos como los relés y las válvulas. En concreto, los métodos R2R implícitos se basan en la idea de construir una función que evalúe el desempeño del sistema al final de cada repetición. De esta forma, es posible mejorar el comportamiento dinámico del actuador a lo largo de las repeticiones utilizando un algoritmo de búsqueda.Las posibilidades para diseñar un controlador R2R son prácticamente infinitas, así que en la tesis se dan consejos prácticos sobre cómo elegir y parametrizar la señal de entrada, cómo usar las medidas disponibles para evaluar el comportamiento del sistema o cómo comparar distintos algoritmos de búsqueda. Los experimentos realizados demuestran que el algoritmo R2R diseñado es capaz de mejorar enormemente el comportamiento de un relé electromecánico y que, después de unos pocos ciclos, ,los resultados son incluso mejores que con cualquier estrategia presente en la literatura.Reluctance actuators are characterized by having a high force density, good efficiency, high fault tolerance and reduced cost. These features make them a promising alternative to other electromagnetic actuators for high-speed and high-precision applications. In addition, reluctance actuators are also ideal for small switch-type devices that require a modest performance because of their compactness, low cost, reduced mass and low energy dissipation. In particular, electromechanical switches and solenoid valves are devices whose operation is based on the force created by a small reluctance actuator. Despite their advantages, reluctance actuators are systems with highly nonlinear dynamics. One of their most distinctive features is that the magnetic force that produces the motion is always attractive and varies greatly with the position of the armature. In essence, the nature of this force explains why switch-type devices like relays and valves are subject to strong impacts and wear each time they are operated. In addition to that, electromagnetic phenomena such as magnetic hysteresis and eddy currents make the dynamic modeling of reluctance actuators even more difficult. The work of this thesis aims to investigate the capabilities of reluctance actuators and, in particular, to analyze the dynamic behavior and propose estimation and control algorithms for electromechanical switches and solenoid valves. The first objective of the investigation is the development of control-oriented dynamical models for reluctance actuators, i.e., low-order models that can be used to perform accurate transient simulations with low computational requirements. For that, the electromagnetic behavior of these systems is firstly studied. The magnetic equivalent circuit (MEC) methodology is selected as the primary modeling technique. Simulations from finite element models are also used for some specific purposes, e.g., to verify the assumptions of the MEC approach or to calculate the reluctance of the air gap. Then, the main electromagnetic phenomena that occur in reluctance actuators are studied. Analytic expressions are derived to model magnetic saturation, hysteresis, flux fringing and eddy currents, and an energy balance is used to obtain the expression for the magnetic force that produces the motion. After that, the motion of the armature is incorporated to the analysis. Given that reluctance actuators usually have a limited range of motion, two different techniques are proposed to model the limits of the armature stroke and the bouncing phenomenon. Then, the electromagnetic equations and the mechanical models are combined to describe the overall dynamic behavior of the actuator. Five different dynamical models are presented, ranging from a computationally inexpensive structure to a comprehensive model that includes saturation, hysteresis, eddy currents and flux fringing. The models are compared in terms of accuracy and computational requirements. Measurements play an important role in the analysis and characterization of dynamical systems. Thus, another objective of this thesis is the evaluation of different measurement methodologies that may improve the understanding of the dynamic behavior of reluctance actuators and, if possible, be used as part of a feedback controller. In this regard, three optical instruments are explored in order to record the motion of switch-type actuators. The results show that, even though in some cases it is possible to measure the position of several components of the device, none of the instruments could be applied in a practical situation due to their low flexibility and high cost. For that reason, other variables that are much more easily obtainable are also explored. Another significant part of the research is devoted to estimation in reluctance actuators. Two different algorithms are proposed to estimate the magnetic flux, the resistance and the inductance of the device, both of which can be implemented in real time. The algorithms rely only on measurements of the coil voltage and current, which represents a clear advantage because no additional hardware is required. Simulation and experiments are presented to show the performance of the estimators. Furthermore, the estimation of the armature position is also investigated in this work. In particular, special focus is put on highlighting the effects of magnetic hysteresis on the performance of different estimation approaches. Control strategies are then proposed to achieve soft landing in reluctance actuators, i.e., a controlled motion without impacts or bounces. As a first step, the basic properties of control systems theory---stability, controllability and stability---are investigated for a nominal actuator. Then, feedback linearization is explored as a method to design a trajectory tracking controller for the armature position. The obtained results show that soft landing can be accomplished by means of feedback control provided that accurate measurements or estimates of the position are available. Since this situation is rare in practice, open-loop optimal control is proposed as an alternative technique when the position is not accessible. Different time-optimal and energy-optimal solutions are derived for a nominal actuator and then compared in terms of robustness using a Monte Carlo analysis. Finally, Run-to-Run (R2R) control is explored as another method that may be used to improve the performance of reluctance actuators. These techniques are specifically designed for systems that perform a repetitive operation and, hence, they are very well suited to being applied to switch-type devices. In particular, implicit R2R methods are based on the idea of building a function that evaluates the performance of the system at the end of each repetition. In this way, the dynamic behavior of the actuator can be gradually improved along the repetitions by conducting a black-box search. Considering that the possibilities to design a R2R controller are almost endless, practical advice is given on how to select and parameterize the input profile, how to use measurements to evaluate the system performance and how to compare different search algorithms. The performed experiments show that the designed R2R controller is able to improve greatly the behavior of a switch-type device and that, after a few cycles, it outperforms other methodologies in the literature.<br /

    An audio-based iterative controller for soft landing of electromechanical relays

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    Electromechanical relays and contactors suffer from strong collisions at the end of the switching operations. This causes several undesirable phenomena, such as clicking, mechanical wear and contact bounce. Thus, there is great interest in mitigating these switching impacts while keeping the advantageous features of these devices. This paper proposes a complete control strategy for soft landing. The control structure includes three main components. The first one is a real-time flux-tracking feedback controller, which presents several advantages over voltage or current control. The second one is a feedforward controller, which computes the flux reference signal based on a proposed dynamical model and the desired position trajectory for the switching operations. Lastly, the third control component is a learning-type run-to-run adaptation law that iteratively adapts the model parameters based on an audio signal. It exploits the repetitive nature of these devices in order to circumvent modeling discrepancies due to unit-to-unit variability or small changes between operations. The effectiveness of the proposed control is demonstrated through various experiments

    Reluctance actuator characterization via FEM simulations and experimental tests

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    Modeling the reluctance of an electromagnetic actuator is a critical step to analyze its dynamics and design model-based controllers. On the one hand, analytical expressions based on either theoretical or empirical models often lack accuracy due to model inconsistencies. On the other, numerical methods are much more precise but require exact information about the system geometry, materials and winding configuration. In this paper we present a new method that brings together the good properties of the finite element method and of system identification techniques to obtain an accurate description of the reluctance and its derivative. Since the method is designed to identify the unknown parameters of the system, it is particularly well suited for modeling existing commercial devices. An application on a safety valve used in gas lines is included to illustrate the method and a discussion on the results shows the advantages of our proposal

    Improved micro-contact resistance model that considers material deformation, electron transport and thin film characteristics

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    This paper reports on an improved analytic model forpredicting micro-contact resistance needed for designing microelectro-mechanical systems (MEMS) switches. The originalmodel had two primary considerations: 1) contact materialdeformation (i.e. elastic, plastic, or elastic-plastic) and 2) effectivecontact area radius. The model also assumed that individual aspotswere close together and that their interactions weredependent on each other which led to using the single effective aspotcontact area model. This single effective area model wasused to determine specific electron transport regions (i.e. ballistic,quasi-ballistic, or diffusive) by comparing the effective radius andthe mean free path of an electron. Using this model required thatmicro-switch contact materials be deposited, during devicefabrication, with processes ensuring low surface roughness values(i.e. sputtered films). Sputtered thin film electric contacts,however, do not behave like bulk materials and the effects of thinfilm contacts and spreading resistance must be considered. Theimproved micro-contact resistance model accounts for the twoprimary considerations above, as well as, using thin film,sputtered, electric contact

    Real-time electromagnetic estimation for reluctance actuators

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    Several modeling, estimation, and control strategies have been recently presented for simple reluctance devices like solenoid valves and electromagnetic switches. In this paper, we present a new algorithm to online estimate the flux linkage and the electrical time-variant parameters of these devices, namely the resistance and the inductance, only by making use of discrete-time measurements of voltage and current. The algorithm, which is robust against measurement noise, is able to deal with temperature variations of the device and provides accurate estimations during the motion of the armature. Additionally, an integral estimator that uses the start of each operation of the actuator as reset condition has been also implemented for comparative purposes. The performances of both estimation methods are studied and compared by means of simulations and experimental tests, and the benefits of our proposal are emphasized. Possible uses of the estimates and further modeling developments are also described and discussed

    Probability-Based Optimal Control Design for Soft Landing of Short-Stroke Actuators

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    The impact forces during switching operations of short-stroke actuators may cause bouncing, audible noise, and mechanical wear. The application of soft-landing control strategies to these devices aims at minimizing the impact velocities of their moving components to ultimately improve their lifetime and performance. In this brief, a novel approach for soft-landing trajectory planning, including probability functions, is proposed for optimal control of the actuators. The main contribution of the proposal is that it considers the uncertainty in the contact position, and hence, the obtained trajectories are more robust against system uncertainties. The problem is formulated as an optimal control problem and transformed into a two-point boundary value problem for its numerical resolution. Simulated and experimental tests have been performed using a dynamic model and a commercial short-stroke solenoid valve. The results show a significant improvement in the expected velocities and accelerations at contact with respect to past solutions in which the contact position is assumed to be perfectly known

    Arcing Failure of ROHS Compliant Electromagnetic Relays

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    Electronic relay contacts have traditionally been made of materials, primarily Ag/CdO, which are resistant to welding under short, high power pulses. However, since 2006, RoHS prohibits the use of cadmium in electronics, driving the elimination of Ag/CdO and its replacement with Ag/SnO2. The reliability of relays made with Ag/SnO2 contacts has been shown to be vendor specific. This thesis focuses on developing an understanding of the metallurgical and design factors that vary by manufacturer and their effect on welding susceptibility of Ag/SnO2 electromagnetic relay contacts and other related relay failure mechanisms. In addition, it aims to predict a safe operating area of power and energy over which specific relay contacts will not weld under high power DC conditions. Relays from various manufacturers were subjected to capacitor discharge pulses of 250 V at 10-80 uF to characterize relay reliability. Failure analysis was then conducted on the welded contacts using scanning electron microscopy (SEM) and wavelength-dispersive spectroscopy (WDS) in order to address material properties and design variations that affect the welding susceptibility of relays. The incidence and extent of degradation is correlated to material characteristics including contact composition, oxide content, hardness, contact geometry, and surface roughness using a physics of failure approach. The relays with a higher percent content of indium oxide exhibited a greater reliability than those without. Both power and energy were then varied to further investigate the one cycle to failure boundary region and a failure map is presented

    On the Stability of Electromechanical Switching Devices: A Study of Hysteretic Switching Behaviors

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    Electromagnetic relays and solenoid actuators are commercial devices that generally exhibit bistable behavior. In fact, this is the reason why they are extensively used to switch between two possible configurations in electrical, pneumatic, or hydraulic circuits, among others. Although the state of the art is extensive on modeling, estimation, and control of these electromechanical systems, there are very few works that focus on analysis aspects. In this paper, we present an equilibrium and stability analysis whose main goal is to provide insight into such bistable behavior. The study is based on a hybrid dynamical model of the system also presented in the paper. This model is used to obtain analytic expressions that relate the physical parameters to the switching conditions. The results are extensively discussed and possible practical applications are also proposed. Finally, experimental results with a real device are used for validation of the theoretical analysis and also for illustrating one of the possible practical uses
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