4 reference designs specialized for preventive maintenance of motors and plungers

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Design Analog Texas Instruments

There is no equipment that never breaks down in any facility. In the unlikely event that a failure occurs, some people may think that they should be repaired at that time, but after a failure or malfunction occurs, the following disadvantages may occur.

Disadvantages of repairing after a failure or malfunction occurs

Loss of productivity due to long downtime
Procurement of parts for repair may take time
There is a possibility that a wide range of defects may occur from the defect location.
The useful life of equipment will be shortened if it is forced to operate without repair.

In order to avoid such disadvantages, maintenance activities called "preventive maintenance" to prevent equipment failures in advance are important.

This article introduces the following four reference designs that specialize in preventive maintenance provided free of charge by Texas Instruments (TI).

Smart solenoid driver with predictive maintenance
Motor monitor with wireless vibration sensor for preventive maintenance
Redundant dual channels for safe torque off of variable speed drives
Current Controlled Driver for 24V DC Solenoid with Plunger Failure Detection

1. Smart solenoid driver with predictive maintenance

Solenoid driver reference design that implements additional monitor control and diagnostic features. It realizes looseness detection of springs, aging deterioration recognition of valves, and dynamic control of solenoid current.

This predictive maintenance feature set helps reduce or prevent factory downtime. In addition, the ability to control solenoid current helps reduce power consumption and extend valve life.

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Article header library 128253 pic01 1 — Example board built from reference design

Features

Solenoid Driver: Based on MSP430™ PWM output with configurable PWM output for different drive currents
Capture current signature with integrated 12-bit ADC

Current signature can be stored in MSP430 FRAM
Single processing function implemented in firmware
moving average
Local extrema detection

Configurable through UART or IO-link

Target application example

Motor Overload Relays & Contactors
Field Actuator: Motor Valve
Field Actuator: Pneumatic Valve
Electric motor starter and brake

TI products used in this design

model number	detail
MSP430FR5969	Wolverine Mixed Signal Microcontroller
TIOL111	TIOL111 IO Link Device Transceiver with Integrated Surge Protection

2. Motor monitor with wireless vibration sensor to enable preventative maintenance

This reference design is a low-power wireless subsystem solution that uses vibration detection to monitor a motor and determine if preventive maintenance is required. The FFT of the vibration data can be sent to another device using either Bluetooth low energy or sub-1GHz wireless protocols.

The low power consumption and wireless capabilities of this subsystem solution allow it to operate from a single coin cell battery, making it small, inexpensive, and located in hard-to-reach locations. This makes it a great alternative for both preventatively avoidable expensive maintenance and large, expensive monitors that require a wired connection.

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Article header library 128253 pic02 1 — Example board built from reference design

Features

Ultra-low power design for 10-year battery life from a single CR2032 coin cell
Mechanical vibration (20ksps) and temperature sensing
Local computation of 2K FFT for vibration spectrum analysis
Programmable wake-up interval for motor diagnostics
Designed for SimpleLink sub-1GHz and Bluetooth Low Energy Wireless Connectivity LaunchPad (LAUNCHXL-CC1350)

Target application example

HVAC system controller
HVAC motor control

TI products used in this design

model number	detail
ADS8866	16-Bit, 1-MSPS, Serial Interface, Micropower, Tiny, Differential Input, SAR
LMT01	LMT01 Precision 2-Pin Temperature Sensor with Pulse Current Interface
OPA2325	Precision, 10-MHz, Low-Noise, Low-Power, RRIO, CMOS Operational Amplifier
REF5030	Low noise, low drift, precision voltage reference
TPS22860	TPS22860 Ultra-Low Leakage Load Switch
TPS61291	Low Iq Boost Converter with Bypass Operation
LAUNCHXL-CC1350*	Simplelink CC1350 LaunchPad Bluetooth and Sub-1 GHz Long Range Radio, Development Kit

*About LAUNCHXL-CC1350 model number
Since the available Sub-1 GHz band differs depending on the country, this product has two types of model numbers that change the circuit around the antenna according to the corresponding band. When purchasing, please refer to the following and select at your own discretion.

LAUNCHXL-CC1350US: For USA and Japan
LAUNCHXL-CC1350EU: for Europe

3. Redundant dual channel for safe torque off of variable speed drives

This design uses a dual-channel isolated STO signal to control the inverter that powers the motor, enabling Safe Torque Off (STO) functionality in variable speed drives according to IEC61800-5-2 .
This function is accomplished by independently enabling or disabling power to the isolated gate driver ICs through the VCC1 and VCC2 load switches.

The reference design also includes diagnostics to detect various faults, enabling an improved safe failure rate.

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Article header library 128253 pic03 1 — Example board built from reference design

Features

Implements Safe Torque Off (STO) function to achieve Stop Category 0 as specified in IEC 61800-5-2
Dual channel STO signal and multiple options to prevent torque generation in the motor

Remove power from gate driver IC (both low voltage and high voltage domains)
Generation of hardware trip signal to terminate PWM generation inside the microcontroller

Extensive self-diagnostics including monitoring of safety pulses, detection of various faults in the circuit, etc.
±60V input tolerance and reverse polarity protection ensure STO pin protection in the event of a fault
Accurate output current monitoring with high-side smart switch
Ready (RDY) pin indication for gate driver input and output undervoltage lockout (UVLO) detection

Target application example

AC inverter and VF drive
fitness machine
manufacturing robot
electric toothbrush

TI products used in this design

model number	detail
ISO1212	Isolated 24V to 60V Digital Input Receiver for Digital Input Modules
ISO5852S	ISO5852S High CMTI 2.5A / 5A, Isolated IGBT, MOSFET Gate Driver with Split Output
LMZ14201	1A SIMPLE SWITCHERR Power Module with 42V Maximum Input Voltage
SN74HC7001	Quad Positive AND Gates, Schmitt Trigger Inputs
TPS22860	TPS22860 Ultra-Low Leakage Load Switch
TPS27S100	40V, 100mΩ single channel smart high side switch
TVS3300	33V Precision Surge Protection Clamp

4. Current controlled driver for 24V DC solenoid with plunger fault detection

This design is a reference design for integrating current control and plunger movement detection into a solenoid coil.

With up to 70% lower power consumption, faster processing times, enhanced monitoring capabilities, and improved ease of use, these benefits can now be applied to a variety of applications, including industrial equipment and material processing. increase.

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Article header library 128253 pic04 1 — Example board built from reference design

Features

PWM-based current control allows power optimization during peak and hold times, as well as power optimization based on fixed time settings
Plunger movement detection allows use of back EMF or Hall sensor based options
Automatically switches from peak to hold current mode upon completion of plunger travel
Generates an alarm signal when the plunger malfunctions, undervoltage occurs, or when controller overheating is detected
Meets EN55011-Class A conducted emissions limits

Target application example

ATM (cash machine)
HVAC valve and actuator control
POS cash register
white goods
Ductless air conditioner outdoor unit
Field Actuator: Motor Valve

TI products used in this design

model number	detail
DRV110	Integrated Power Saving Solenoid Controller, Power Regulator
DRV5023	DRV5023 Digital Switch Hall Effect Sensor
OPA4170	36-V, Ultra-Low-Power, Rail-to-Rail Output, 4-Channel, General-Purpose Op Amp
TLV271	550 μA/Channel 3 MHz Rail-to-Rail Output Operational Amplifier