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| | c c c
+ + =
|
c c c
\ .
2 2 2
2 2 2 2 2 2
(1)
T: Temperature of the object
: Coefficient of heat conductivity
: Heat of formation in unit volume
Boundary condition:
( )
f
T
T T
n
o
c
=
c
0
(2)
: surface coefficient of heat transfer
T
0
: temperature of heating element
T
f
: environmental temperature
The natural convection of solenoid valve is mainly between
external surface of wind and magnetic yoke and air. Therefore,
Convection hot coefficient is applied in the external surface of
wind and magnetic yoke.
magnet
yoke
Encapsulate
layer
skeleton
screw
Coil
Static core
Movable
core
sleeve
Proceedings of ICEC-ICREPEC2012
3) Calculation of equivalent heat transfer coefficient of coil
Coil is one of the main heating elements which will affect
the life of solenoid valve directly. It is mixed with epoxy
encapsulate and copper. Therefore, the coefficient of heat
conduction of copper can`t instead of that of coil. The
temperature of coil can be solved through the calculation of
equivalent heat transfer coefficient of coil.
4) Calculation of coupling of thermal and electric
In recent years, more and more scholars calculate the
temperature distribution of electromagnetic mechanism using
finite element software based on the existing power. The model
can be built simply and will get the exactly result if the input
power is right. However, the eddy-current loss of the exchange
electromagnetic mechanism cannot be calculated exactly.
B. Calculation of Temperature Field
For the factor as following: eddy-current loss exists in the
AC solenoid valve; the coil resistivity, coefficient of heat
conduction and the coefficient of heat transfer of every part
varies with temperature; heating and cooling interacts with
each other. Therefore, the AC solenoid valve temperature can
be calculated through thermoelectric coupling. The flow chart
is shown in fig.3.
suppose initial ambient
temperature T0, coil
temperature T1=T0
power loss calculation of
each part
calculate coil resistivity
electromagnetic calculations
based on ansys
temoerature calculations
based on ansys
calculate coil average
temperature T2
|T2-T1|<c?
coil constant temperature T2
Modify coil temperature
T1=T2
N
Y
Fig.3 Calculation flow chart
First, using the loss of heating elements as load and the
steady temperature calculation of solenoid valve can be
calculated through electromagnetic field. As the coil resistivity
varies with temperature, the power loss calculated in normal
temperature is quite different from that in high temperature.
However, it can be solved by iterative repetition. Firstly, the
initial temperature of the coil is set as ambient temperature.
The power loss of heating elements can be calculated through
electromagnetic field and the temperature distribution is solved.
According to the coil temperature, the new resistivity can be
put into the electromagnetic field for next calculation. The loop
computing function will be ended until the temperature
difference between the near two times is less than 0.5, and
the heat productivity equals to the heat release. The
temperature is steady.
The temperature distribution with rated voltage is shown in
fig.4.
Fig.4 Temperature distribution of solenoid valve
movable-core, static core, shading coil, magnetic yoke,
skeleton, epoxy layer, sleeve, coil, cut-open view of coil.
In fig.4, the maximum, minimum temperature rise and the
temperature distribution can be seen clearly. And the
temperature rise change in long term can be got. Meanwhile,
the temperature rise change can be brought into the
optimization design program of electromagnetic mechanism for
comprehensively optimal design.
III. OPTIMAL DESIGN METHOD
A. Ant Colony Optimization
Ant colony algorithm is a kind of swarm intelligent
algorithm based on simulating ants` looking for food. They will
leave a kind of material called pheromone on the passing road
in the process of looking for food and perceive the strength
which will lead them to the right direction. It is a positive
feedback phenomenon for the ants` collective foraging. The
shorter of the road, the more of the ants and the pheromone are.
Therefore, the chance that ants choose will be higher. It
comprises the positive feedback process and then approaches
the optimal path gradually and finally the optimal solution can
be found.
Proceedings of ICEC-ICREPEC2012
The specialties of the ant colony optimization algorithm are
shown as following:
It belongs to intelligent optimization algorithms as genetic
algorithm. It possesses the specialties of essence parallel and
self-adaption. And it behaves more excellent performance in
the aspect of combinatorial optimization
[6, 7].
It overcomes the defect in the solving process of the
traditional deterministic optimization algorithm. There is no
request of differentiability and convexity on the object function.
It doesn`t need the derivate information and has global
optimization ability. The robustness and generality is strong
and it applies to parallel processing. It is also easy to combine
with other algorithm and the performance can be improved.
Comparing to other intelligent optimization algorithms such as
genetic algorithm, positive feedback system of ant colony
algorithm has an ability to find out a better solution. For some
improved ant colony algorithm, they have superiority in
solving efficiency and global optimization
[8, 9].
As a kind of parallel optimization algorithm, it can solve
many feasible not dominate solutions when it used in the multi-
objective optimization problem and it has advantages that
single objective optimization method cannot compare.
Therefore, it is adequate for multi-objective optimal design
based on Pareto
[10, 11].
Ant colony optimization algorithm is applied widely in
project for its prominent feature. It is mainly used in the field
of discrete combinatorial optimization and continuous function
optimization. There are two mainly solutions for the continuous
optimization problems. One is making the ant as the peak point,
and the pheromone distributes directly on every ant`s position
on the solution space. Another way is dispersing every
component into fixed interval and views every component as
peak point, and then the pheromone distributes in the
subinterval of every component.
In this paper, the latter way is used. According to the basic
mathematical model, there are five steps in the solution:
mapping, parameters realization, probability choosing,
pheromone updating and iteration end condition. The flow
block of Ant colony algorithm shows in fig.5
B. Choice of Optimization Parameters
1) Optimization parameters
The structure of L valve and L coil shows in fig6.
The Optimization variables chosen as following:
[ , , , , , ]
T
x x x x x x x =
0 1 2 3 4 5
(3)
`0=Diameter of the coil wire
`1=N=Turns of the coil
`2=hd=Thickness of the magnetic yoke
`3=d2=Diameter of static core
`4=d1=Diameter of movable core
`4=Inner diameter of coil.
Start
Initialize optimizing interval.
ants.pheromone et.
Gridding less than the
setting precision ?
Iterations t=1
Ants counting
s=1
Output
optimal
solution
End
Ant S selects i+1 dimension
optimal variant according to
pheromone strength
s=s+1<m?
Dimension
counting i=1
i=i+1<n?
t=t+1<the maximum
iterations T?
Ipdata i+1 dimension
information locally in each
interval
Update pheromone
global
Reduce the
range of
variable value
Y
Y
Y
Y
N
N
N
N
Calculate every ant`s target
function and save the
information of optimal solution
Fig.5 The flow block of Ant colony algorithm
Fig.6 the Structure of L valve and L coil
2) Target function
The paper chooses some indexes which reflect the whole
index of economy and technology and the picking up time
which meet its action characteristics as target function for
optimization.
Proceedings of ICEC-ICREPEC2012
min ( ) [ ( ), ( ), ( ), ( )]
T
Fe cu k
f x V x V x E x T x = (4)
VFe(X) =Iron volume
VCu(X) =Copper volume
Ek(X)= 0.5mv
2
= Impact energy per unit area of the core area
T(X) = the picking up time of the electromagnetic mechanism
3) Constraint conditions
The constraint conditions are decided by the technical
requirements and performance characteristics. Firstly, it should
be closed reliably in any closing phase angle. Secondly, the
coil temperature rise should be lower than 75 in long
working term with 50as the ambient temperature and 1.06
times of the rated voltage.
4) Extermal function
A single extreme value function will be constituted by the
multiple objective functions sum up with different weighting
factor. And then, it solves through the optimization method
of single objective function. The extremal function is
following:
( ) ( ) ( ) ( )
( )
cu Fe k
cu Fe k
V x V x wE x wT x
F x w
V V E T
o | | |
= + + +
|
\ .
2 3
1
0 0 0 0
(5)
VFe0, VCu0, Ek0, T
0
: as the objective function values before
optimization.
W
1
, W
2
, W
3
: as the weighting actors for each objective
function. In this paper, it makes +=1, W
1
+W
2
+W
3
=1, and
takes cost effectiveness and good properties for main objective
of optimization.
Taking W
1
=W
2
=0.495, W
3
=0.01. According to price
provided by the producer, copper is 85RMB per kilogram, iron
is 15RMB per kilogram. Making=0.85, =0.15.
In the optimal design of solenoid valve, closed reliably and
the steady temperature rise are key factors. The temperature
solved just considering resistance loss will be quite different
from the fact. The model should be corrected.
IV. OPTIMIZED CALCULATION OF AC SOLENOID VALVE
A. Analyses on Coil Average Temperature rise
Coil loss, hysteresis and eddy current losses of ferromagnet
and power loss of shading coil are main reasons causing the
temperature rise. Therefore, diameter of coil wire, turns of coil,
thickness of magnetic yoke, diameter of core and so on will
affect solenoid valve temperature rise seriously and the regular
is very complicated. Meanwhile, 3D field calculation is very
time-consuming and it needs much resource. The paper
analyzes the regular of temperature rise of the main elements in
order to build a correct model.
According to the manufacturer`s request for the product, the
paper takes AC200 as the object for analyzing.
All kinds of power loss in different diameters of coil wire
and turns solved in electromagnetic field are listed in TABLE I.
TABLE I POWER LOSS IN DIFFERENT DIAMETER OF ENAMELED WIRE LINE
AND COIL TURNS
Xj
mm
N
Coil loss
W
Other
loss
W
Total
loss
W
Coil loss
percentage
%
0.06
8000 3.92 1.37 5.29 74.1
8500 3.31 1.33 4.64 71.34
9000 2.77 1.28 4.05 68.4
9500 2.32 1.21 3.53 65.72
0.063
8000 4.03 1.45 5.48 73.54
8500 3.30 1.4 4.70 70.21
9000 2.72 1.32 4.04 67.33
9500 2.33 1.25 3.58 65.08
0.071
8000 3.97 1.65 5.62 70.64
8500 3.13 1.58 4.71 66.45
9000 2.44 1.50 3.94 61.93
9500 2.00 1.41 3.41 58.65
Xj means the diameter of coil wire and the unit is mm. N
means the turns of coil. From TABLE I we can see that coil
power loss takes about 58%-75% of the total power loss, it is
the main factor causing the temperature rise of solenoid valve.
Diameter of coil wire and turns are main reasons causing the
coil loss. Based on the 3D temperature simulation, summarize
the regular of the temperature varies with diameters of coil
wire and turns, and then adjust the model.
B. Coil Temperature Calculation of AC220-240
Input voltage is 1.06 Ue (Ue means the rated voltage.), that
is 254.4V. Fill factor of coil is 0.55, and ambient temperature is
50. The coil average temperature in different coil turns and
wire diameters are calculated. Cvxpt32 is a kind of data fitting
software which is used for fitting of 2D data. It supplies many
kinds of nonlinear model. Fitting the calculated data with
cvxpt32 and getting the relation of temperature and coil turns
in different wire diameter which fits in with fixed geometric
model.
( )
b
N
T aN A = (6)
The value of a, b is different in different wire diameters.
TABLE II shows the fitting result.
Proceedings of ICEC-ICREPEC2012
TABLE II RELATION OF TEMPERATURE AND COIL TURNS
Xj/mm N .T /
Fitting .T=a*N^(b/ N)
a b .T /
0.06 9000 107.3 4.699 3092.238 107.3
0.06 9500 92.7 4.699 3092.238 92.6
0.06 10000 80.7 4.699 3092.238 81.1
0.06 10500 72.4 4.699 3092.238 71.8
0.06 11000 64.0 4.699 3092.238 64.3
0.063 9000 106.4 4.337 3168.824 104.6
0.063 9500 93.0 4.337 3168.824 90.5
0.063 10000 80.2 4.337 3168.824 79.4
0.063 10500 72.1 4.337 3168.824 70.4
0.063 11000 62.0 4.337 3168.824 63.2
0.071 9000 101.2 5.108 2941.042 100.1
0.071 9500 85.8 5.108 2941.042 87.0
0.071 10000 75.2 5.108 2941.042 76.7
0.071 10500 69.6 5.108 2941.042 68.3
0.071 11000 61.9 5.108 2941.042 61.5
0.08 9000 99.0 5.349 2869.293 97.5
0.08 9500 83.0 5.349 2869.293 85.0
0.08 10000 74.0 5.349 2869.293 75.2
0.08 10500 68.2 5.349 2869.293 67.2
0.08 11000 61.3 5.349 2869.293 60.6
.T means temperature rise. Fitting the relation between a, b
and wire diameters using cvxpt32. And the result as follows:
2
1
0.428 5.302* 28.64*
j j
a
x x
=
+
(7)
1
0.378
4296.855*1.045 *
j
x
j
b x = (8)
Integrate the Eq.(6)-(8) and get the last equation as follows:
1
0.378
4296.855*1.045 *
2
0.428 5.302* 28.64*
x
j
j
x
N
j j
N
T
x x
A
| |
|
|
|
\ .
=
+
(9)
Contrast the results calculated from Eq. (9) and that from the
simulation. TABLE III shows a part of the contrast result.
TABLE III DATA CONTRAST
Xj/mm N
.T from
software/
.T from
formula/
Relative
error
0.06 10350 74.4 74.2 0.27%
0.063 10350 72.7 72.7 0
0.071 10350 71.6 70.5 1.54%
0.08 10350 70.5 69.2 1.86%
TABLE III shows that Eq.(9) will show the relation correctly
between wire diameters, coil turns and coil temperature when
the input voltage is 1.06 times of the rated voltage.
For AC200 solenoid valve, when it input 1.06 times rated
voltage and the ambient temperature is 50. Fitting the data,
and then getting that the relation falls in hyperbolic model as
following:
1
* T a b
N
A = + (10)
The fitting process is similar to that of AC220-240. The
relation between a, b and wire diameters shows as following:
2
87.561 843.111*
1 11.558* 13.071*
j
j j
x
a
x x
+
=
+
(11)
2
1507431.135 14557635.63*
1 9.695* 3.817*
j
j j
x
b
x x
=
(12)
Integrate the Eq. (11) - (12) and get the last equation as
following:
2
2
87.561 843.111*
1 11.558* 13.071*
1507431.135 14557635.63*
1
*
1 9.695* 3.817*
j
j j
j
j j
x
T
x x
x
x x N
A
+
=
+
+
(13)
The optimal process of solenoid valve considered
temperature shows in fig.7.
C. Example of optimization
The result showed in TABLE IV using the process showed
in fig.5.
After the optimization, the copper volume reduces 24.4%
and the impact energy reduces 2.59%. The result is satisfied.
The solenoid valve after optimization is produced in the
process.
Furthermore, other optimal parameters and target functions
can be reset according to the request for the global optimal
design.
Proceedings of ICEC-ICREPEC2012
Start
Initialize optimizing interval.
ants.pheromone et.
Gridding less than the
setting precision ?
Iterations t=1
Ants counting
s=1
Output
optimal
solution
End
Ant S selects i+1 dimension optimal variant
based on Roulette wheel selection according to
pheromone strength
s=s+1<m?
Dimension
counting i=1
i=i+1<n?
T=t+1<the
maximum
iterations T?
Ipdata i+1 dimension information
locally in each interval
Update pheromone
global
Reduce
The
range of
numeric
area
Y
Y
Y
Y
N
N
N
N
Ant S call dynamic calculation
program
Calling closed optimal
program
Solving the
objective function
Ants counting
s=1
s=s+1<m?
Saving the minimum value of the minimum
target function in the ants
Y
N
Closed reliable in set time
Temperature rise
calculation module
3D electromagnetic and
temperature field module
Meeting the request of
optimal target
Adjust
the
optimal
variant
affecting
the
closing
process
Y
N
Adjust coil
optimization variables
Is it feasible for
machining
Y
N
Meeting optimization
structure
Y
N
N
Y
Every ant
chooses
one
dimen-
sion
optimal
variant
based on
roulette
wheel
selection
and
updates
the
pheromon
e strength
in each
Interval
until ant
m finish
the choice
of the
first
dimensio
n optimal
Variant
Interval
Fig.7 Optimal process of solenoid valve considered temperature
Proceedings of ICEC-ICREPEC2012
TABLE IV OPTIMAL RESULT
Before
optimization
After
optimization
Xj/mm 0.09 0.08
N 8700 8550
Copper volume/mm3 74.94 58.9
Closed time/ms 5.44 5.54
impact energy/J 0.0116 0.0113
.T from formula / 74.2 74.03
.T from software/ 72.4 72.22
relative error of .T /% 2.49 2.51
V. CONCLUSIONS
In this paper, it makes FDF series solenoid valve as object to
build the simulation analytical system including calculation of
dynamic characteristic and temperature rise, dynamic
characteristics analysis and global optimal design. The ant
colony optimization is brought into the optimal design. With
the specialties of small volume and high temperature rise, the
paper brought the temperature calculated from ANSYS into the
program which calculates the coil average temperature. And
the result is satisfied. It lays a foundation for global optimal
design.
REFERENCES
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BIOGRAPHIES
Xu Zhihong, was born in Shanxi,China. She
received her B.S,M.S and ph.D degrees from Fuzhou
University, China in 1983,1997, and
2005respectively, all with electrical engineering
major. Since 1983, she works as teacher in the
Department of Electrical Engineering of Fuzhou
University. She is now a professor and a doctor tutor
in College of Electrical Engineering and Automation of Fuzhou
University, taking charge of teaching and research. Her research
interesting is in the Artificial Intelligent and On-line Monitoring
Technology.
Lin Shuyi, was born in Fujian, China. She is a doctor candidate in
College of Electrical Engineering & Automation, Fuzhou University.
She received her B.S degree from Fuzhou University, China in 2008
with electrical engineering major Her research interesting is in the
Artificial Intelligent and On-line Monitoring Technology