Variable force solenoid

Last updated

A variable force solenoid (VFS) is an electro-hydraulic device that controls pressure proportionally or inversely proportionally to a signal (voltage or current) obtained from the on-board controller of a powertrain. A low flow VFS is used as a signal level devices for transmission line pressure control or application of clutches. A high flow VFS controls line pressure directly or are used for direct shift clutch control. A VFS is a type of Transmission Solenoid. One or more VFS can be used in an automatic transmission or installed in an automatic transmission valve body. [1]

Contents

Theory of operation

A variable force solenoid includes:

In the steady-state condition, the typical VFS design intent is to control pressure by balancing three axial forces:

The VFS can be designed such that any of these forces act in either axial direction. If the magnetic force acts opposes the pressure force, then increasing current through the solenoid coil will, at steady-state, cause an increase in VFS output pressure. This is commonly called a "proportional" VFS since controlled output pressure increases with controlled current. In the absence of current, this design produces low pressure, so it can also be called a "normally low" solenoid. If magnetic force acts in the same direction as the pressure force, then increasing current will cause a decrease in controlled pressure. This can be called an "inversely proportional" or "normally high" solenoid.

Other forces can modify the resulting controlled pressure output from the VFS. These include

A typical design error for variable pressure controlled electrohydraulic devices involves a poorly controlled minimum working air gap. When this occurs, the magnetic circuit reluctance drops rapidly at high current & small working air gaps, and magnetic force rises rapidly. This is observed as a "stuck" valve where pressure follows the design intent until a specific point of operation - typically the highest pressure for a normally high or the lowest pressure for a normally low solenoid - at which point a small reversal of current does not cause the expected change in pressure.

Magnetic circuit

A typical magnetic circuit is driven by a coil winding with controlled current in order to develop a magnetic flux across a working air gap. Out of necessity there is a circular air gap that can only provide radial force (also known as side loading). These two air gaps dominate the magnetic circuit reluctance. The rate of change of the working air gap stored energy provides the axial magnetic force.

The images below show flux lines and field density for an example solenoid design [2]

Solenoid Magnetic Ckt.jpg

Related Research Articles

Valve Device that controls the flow of a fluid

A valve is a device or natural object that regulates, directs or controls the flow of a fluid by opening, closing, or partially obstructing various passageways. Valves are technically fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a direction from higher pressure to lower pressure. The word is derived from the Latin valva, the moving part of a door, in turn from volvere, to turn, roll.

Electromagnet Type of magnet in which the magnetic field is produced by the flow of electric current

An electromagnet is a type of magnet in which the magnetic field is produced by an electric current. Electromagnets usually consist of wire wound into a coil. A current through the wire creates a magnetic field which is concentrated in the hole, denoting the center of the coil. The magnetic field disappears when the current is turned off. The wire turns are often wound around a magnetic core made from a ferromagnetic or ferrimagnetic material such as iron; the magnetic core concentrates the magnetic flux and makes a more powerful magnet.

Solenoid

A solenoid (,) is a type of electromagnet, the purpose of which is to generate a controlled magnetic field through a coil wound into a tightly packed helix. The coil can be arranged to produce a uniform magnetic field in a volume of space when an electric current is passed through it. The term solenoid was coined in 1823 by André-Marie Ampère to designate a helical coil.

A transducer is a device that converts energy from one form to another. Usually a transducer converts a signal in one form of energy to a signal in another.

Rack and pinion Type of linear actuator

A rack and pinion is a type of linear actuator that comprises a circular gear engaging a linear gear, which operate to translate rotational motion into linear motion. Driving the pinion into rotation causes the rack to be driven linearly. Driving the rack linearly will cause the pinion to be driven into a rotation. A rack and pinion drive can use both straight and helical gears. Though some suggest Helical gears are noted for “quieter” operation, there is no science to support this theory. Helical racks while being more affordable, have proven to increase side torque on the datums, increasing operating temperature leading to premature wear. Straight racks require a lower driving force and offer increased torque and speed per percentage of gear ratio which allows lower operating temperature and lessens viscal friction and energy use. The maximum force that can be transmitted in a rack and pinion mechanism is determined by the tooth pitch and the size of the pinion as well as the gear ratio..

An actuator is a component of a machine that is responsible for moving and controlling a mechanism or system, for example by opening a valve. In simple terms, it is a "mover".

Dynamic braking Dynamic braking is the use of the traction motors as generators when slowing a vehicle.

Dynamic braking is the use of an electric traction motor as a generator when slowing a vehicle such as an electric or diesel-electric locomotive. It is termed "rheostatic" if the generated electrical power is dissipated as heat in brake grid resistors, and "regenerative" if the power is returned to the supply line. Dynamic braking reduces wear on friction-based braking components, and regeneration lowers net energy consumption. Dynamic braking may also be used on railcars with multiple units, light rail vehicles, electric trams, trolleybuses, and electric and hybrid electric automobiles.

Fluid power

Fluid power is the use of fluids under pressure to generate, control, and transmit power. Fluid power is subdivided into hydraulics using a liquid such as mineral oil or water, and pneumatics using a gas such as air or other gases. Compressed-air and water-pressure systems were once used to transmit power from a central source to industrial users over extended geographic areas; fluid power systems today are usually within a single building or mobile machine.

Dynamometer Machine used to measure force or mechanical power

A dynamometer or "dyno" for short, is a device for simultaneously measuring the torque and rotational speed (RPM) of an engine, motor or other rotating prime mover so that its instantaneous power may be calculated, and usually displayed by the dynamometer itself as kW or bhp.

Hydraulic machinery type of machine that uses liquid fluid power to perform work

Hydraulic machines use liquid fluid power to perform work. Heavy construction vehicles are a common example. In this type of machine, hydraulic fluid is pumped to various hydraulic motors and hydraulic cylinders throughout the machine and becomes pressurized according to the resistance present. The fluid is controlled directly or automatically by control valves and distributed through hoses, tubes, or pipes.

Solenoid valve

A solenoid valve is an electromechanically operated valve.

Motor drive

Motor drive, or simply known as drive, describes equipment used to control the speed of machinery. Many industrial processes such as assembly lines must operate at different speeds for different products. Where process conditions demand adjustment of flow from a pump or fan, varying the speed of the drive may save energy compared with other techniques for flow control.

Axial piston pump

An axial piston pump is a positive displacement pump that has a number of pistons in a circular array within a cylinder block. It can be used as a stand-alone pump, a hydraulic motor or an automotive air conditioning compressor.

A boost controller is a device to control the boost level produced in the intake manifold of a turbocharged or supercharged engine by affecting the air pressure delivered to the pneumatic and mechanical wastegate actuator.

Hydraulic motor

A hydraulic motor is a mechanical actuator that converts hydraulic pressure and flow into torque and angular displacement (rotation). The hydraulic motor is the rotary counterpart of the hydraulic cylinder as a linear actuator. Most broadly, the category of devices called hydraulic motors has sometimes included those that run on hydropower but in today's terminology the name usually refers more specifically to motors that use hydraulic fluid as part of closed hydraulic circuits in modern hydraulic machinery.

A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed by a signal from a controller. This enables the direct control of flow rate and the consequential control of process quantities such as pressure, temperature, and liquid level.

Electromagnetic clutch

Electromagnetic clutches operate electrically but transmit torque mechanically. This is why they used to be referred to as electro-mechanical clutches. Over the years, EM became known as electromagnetic versus electro-mechanical, referring more about their actuation method versus physical operation. Since the clutches started becoming popular over 60 years ago, the variety of applications and clutch designs has increased dramatically, but the basic operation remains the same today.

A shutdown valve is an actuated valve designed to stop the flow of a hazardous fluid upon the detection of a dangerous event. This provides protection against possible harm to people, equipment or the environment. Shutdown valves form part of a safety instrumented system. The process of providing automated safety protection upon the detection of a hazardous event is called functional safety.

An electrohydraulic servo valve (EHSV) is an electrically-operated valve that controls how hydraulic fluid is sent to an actuator. Servo valves are often used to control powerful hydraulic cylinders with a very small electrical signal. Servo valves can provide precise control of position, velocity, pressure, and force with good post-movement damping characteristics.

Directional control valves (DCVs) are one of the most fundamental parts of hydraulic and pneumatic systems. DCVs allow fluid flow into different paths from one or more sources. DCVs will usually consist of a spool inside a cylinder which is mechanically or electrically actuated. The position of the spool restricts or permits flow, thus it controls the fluid flow.

References

  1. Wang, Yanying (2001). "Dynamic modeling of a variable force solenoid and a clutch for hydraulic control in vehicle transmission system". American Control Conference, 2001. Proceedings of the 2001. 3: 1789–1793.
  2. "HomePage:Finite Element Method Magnetics".