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Proceedings of ICEC-ICREPEC2012

Optimal Design and Analysis System of AC Solenoid


Valve

Xu Zhihong, Lin Shuyi, Cheng Zhuyuan
School of Electrical Engineering
Fuzhou University, Fuzhou 350108, China
E-mail: xuzhihong2008@yahoo.com.cn


AbstractSolenoid Valve is a kind of typical low voltage
electrical appliance with special working characteristic. Take
FDF (FDF is a series of model of solenoid valve Sanhua company
produces) series solenoid valve for example which applied widely
in refrigerating system. Its temperature rise, vibration noise and
so on are key points affecting the product quality. At present, the
research on solenoid valve mostly specific to the field in system
response time and structure design and it lacks the analysis on
the overall performance indexes and optimal design. Therefore,
the development of miniaturization, less consumption of the
energy and the artificial intelligence of solenoid valve will be
restrained. The simulation analyzing system for dynamic
characteristic and temperature calculation in working state,
dynamic characteristic analysis and integrated optimized design
is built and it forms unique database of electrical appliance
characteristic analysis and simulation design. It focuses on
optimization design module in this paper. The changing
regularity of the temperature rise of the electromagnetic
mechanism is researched and concluded based on the 3D
simulation in electromagnetic and temperature field. And the
regular is brought into the optimization design of electromagnetic
mechanism. Ant colony optimization is used in the optimal design
for the overall performance index, and the dynamic process of
the closing state and closed in long term working state are also
considered at the same time. The design result is quite satisfied.
Keywordsoptimal design; temperature characteristic; the ant
colony optimization; solenoid valve
I. INTRODUCTION
Solenoid valve is a big branch in actuator of automation
instruments. It can be used in the on-off control of water, air
and neutral. It is also an indispensability part in the safety chain
safeguard system [1]. FDF series AC solenoid valve is applied
widely in the refrigeration industry with the characteristic of
small size, compact structure limit in the working
temperature rise and so on. In recent years, the request on the
solenoid valve is higher and higher. The traditional design
procedures and design concepts cannot meet the faster
development requirement. The design concepts connecting
theory research and experimental verification are used and the
design procedures combine of 'Iield and 'road are taken.
And the simulation analysis system is built including the
calculation of dynamic characteristic of solenoid valve and the
working temperature rise, the analysis of dynamic
characteristic and the overall optimization design. It forms a
unique database with characteristic analysis and simulation
design on electrical product.
The system can be divided into three parts as showing in
fig.1: the calculation of dynamic characteristic, the analysis of
working performance and optimization design. In the module
of dynamic characteristic calculation, the calculation program
in the closing and closed state are built according to the
magnetic circuit characteristic of solenoid valve. And the
regular of the flux, linkage, displacement, speed, suction,
counter-force, current and voltage varying with time in the
closed state can be calculated and the whole process can be
seen clearly. At the meantime, the temperature rise and
equations of the magnetic circuit after the solenoid valve closed
is built. The effect caused by the temperature, shading coil and
so on to the mechanism in long-term working state can be
analysed directly. In the analysis module, the effect of different
closing phase angle, voltage, structure parameters, material and
so on to the characteristic of electromagnetic mechanism can
be analysed conveniently. In the optimization design module,
the ant colony optimization is brought into the optimization
design, and the result calculated through 3D temperature field
is combined especially. The magnetic circuit optimization
design model is corrected. The core and wind parameters
varying with temperature in the long-term working state are
considered. And the result of the overall optimization of the
mechanism is satisfied. It applies a new concept for the
optimization design of the small electrical appliances.
The optimization design module is mainly introduced as
following. In recent years, different kinds of optimization
design methods are applied in the optimization design of
electrical product and the performance indexes are improved

[2-5]. However, the processes are mostly based on dynamic
calculation of electromagnetic mechanism. And the changing
of temperature rise during long term working after optimization
design and the influencing factor are not considered. For the
small-scale product such as FDF solenoid valve, the
temperature rise in long term working and the temperature
change in core and coil will affect its performance index
directly. And this is one of the specialties in the design.
Based on the 3D temperature field simulation, looking for
the influencing factor generated from temperature in long
term working state, combining with magnet circuits`
calculation, bringing it into the optimal design, the result is
satisfied.
Fujian National Science Foundation Project (2011J01295).
Sanhua Company Sponsored Project
Proceedings of ICEC-ICREPEC2012
Simulation and optimal design
system of solenoid valve
Dynamic
calculation
Characteristic
analyze
Platform of
dynamic
calculation
in closing
process
Platform of
dynamic
calculation
in closed
state
Parameters
setting
Dynamic
calculation
in closing
process
Parameters
setting
Dynamic
calculation
in closed
state
Parameters
setting
Characters
showing
Function
operation
System loading
Selection of
solenoid valve
Optimal
design
Parameters
setting
Parameters
before and
after
optimization
Function
operation

Fig.1 Diagram of simulation system of solenoid valve

II. 3D TEMPERATURE FIELD CALCULATION
A. Mathematical Model of Temperature Field
Take the FDF series AC solenoid valve as object of this
study. The model based on ANSYS is built. The cut-open view
of the model is showed in fig.2.












Fig.2 Cut-open view of AC solenoid valve
The following assumptions are made during the calculation
of temperature field.
The solenoid valve is in the infinite space;
The properties of the material are the same;
The external surface thermal convection of the solenoid
valve is natural thermal convection.
1) Confirm of heat source
For the effect of the alternating magnetic field, there will be
hysteresis and eddy current losses in the ferromagnet while the
coil with core and iron fed with AC current. Therefore, the heat
source includes resistance loss generated from resistance,
hysteresis and eddy current loss of moving core, static core and
magnetic yoke, shading coil loss, sleeve loss and so on.
2) Analysis of heat dissipation process
There are three forms of heat conduction as conduction,
convection and radiation. And radiation is ignored in this
model. 3D heat conduction equation inside the solenoid valve
in the steady state as following:


T T T
q
x y z

| | 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.
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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

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