Analog Dialogue 38-04, April (2004) 1

Current Measurement in Solenoids

for Automotive Control Systems
By Scott Beversdorf [[email protected]]
Chuck Whiting [[email protected]]
Solenoids in Automotive Control Applications
A solenoid is a linear motor with a fxed range of travel. Solenoids
may be designed for simple on-off applications, acting much
like relays. For example, they are used this way in starters and
door locks.
On the other hand, a linear, or proportional, solenoid is one whose
position can be controlled in a precise manner. They are used to
operate pistons and valves for accurate control of fuid pressure or
fow in applications such as transmissions and fuel injection.
Transmissions require accurate and smooth control of pressure on
clutches to change gears, and for controlling the locking torque
converter. Electronically controlled transmissions may contain
more than eight linear solenoids, all of which require smooth,
accurate control. Common-rail diesel fuel-injection applications,
with pressures in excess of 2000 psi, may require one linear
solenoid per cylinderand one at the fuel pumpto adjust
pressure accurately to maintain predictable injector fuel fow.
Example: Electronic Transmission Control
The automatic transmission is one system in which electronic
control is largely supplanting mechanical control because of
improvements in drive quality and fuel efficiency. Previous
improvements in fuel effciency and acceleration came with the
introduction of the locking torque converter. More recently,
a combination of software and hardware using electronically
controlled solenoids allowed easier adjustment of the shift
algorithms, and provided additional benefts in transmission-
shift smoothness and quality.
Overall, electronic control of the transmission allows for a simpler,
more reliable, and less costly electromechanical system. Electronic
transmission control systems improve the control of transmission
shift points, with less abrupt gear shifting and improved shift
smoothness. In addition, the fexibility of the electronic control
allows for better adaptability to changing conditions. Electronic
control of shift points with f iner resolution allows better
acceleration, improved economy, better load control, and reduced
emissions, with minimal effort by the driver. In addition, the
electronic control allows the transmission to shift more smoothly
with varying load and acceleration.
With an electronic control system it is possible to affect the shift-
control algorithm by a variety of inputs in addition to shaft speed,
vacuum, and driver input. Some of these parameters include spark
advance, injector parameters, input speed sensors, shift selection
by wire, engine speed, throttle position, torque-converter speed/
lock, ATF temperature, engine temperature, wheel-slip sensors,
and inertial sensors. Combining these kinds of inputs allows a
wide variety of shift optimization points, adapted to the overall
operating conditions. To use these inputs most effectively, it is
necessary to have a system benefting by precise and infnitely
adjustable electronic control of the shift points and shift speed.
Hydraulic control is still used to change gears in the electronically
controlled automatic transmission. In contrast to the mechanical
system (see Appendix), electronic control of the hydraulics in
the electromechanical system is executed by linear solenoids that
vary the hydraulic pressure applied to the actuators attached
to the clutch packs. In order for this to work, it is extremely
important to have accurate and repeatable control of the solenoid
openingwhich in turn allows for accurate, repeatable control
of the shift points through the application of precise amounts
of hydraulic fuid.
Determining Solenoid Position
The linear solenoids position is controlled in a feedback loop. For
example, a valves downstream pressure can be monitored and
used as a feedback signal to compare with the setpoint, adjusting
the pulse-width modulation (PWM) duty cycle to control the
solenoid. However, it may be diffcult, impractical, or very costly
to measure the downstream pressure.
A practical alternative is to establish the position of the
solenoid by measuring the current through the solenoid. This
is possible because the force imposed by the mechanical load on
a solenoid is directly proportional to the magnetic feld, which,
in turn, is directly proportional to the current through the coil.
Proportional control of the solenoid is achieved by a balance
of the forces between the spring-type load and the solenoids
magnetic feld, which can be determined by measuring the
current through the solenoid.
PWM Solenoid Control
The solenoid is powered by using a microcontroller-generated
pulse-width modulated input signal to rapidly open and close a
FET switch in series with the solenoid and a voltage source (the
cars battery). The average voltage is determined by the ratio of
the waveforms on time to the pulse period. Changes in the pulse
width and the solenoids mechanical load cause the average current
fowing through the solenoid to change. The average current is
indicative of the amount of solenoid movement, and thus, fuid
pressure and fow.
The relationship between solenoid movement and average
current for a particular PWM waveform is established through
characterization. While it is true that the magnetic force directly
relates to the current through the solenoid, the actual mechanical
force and movement are not so closely correlated, since they
depend on the construction of the solenoid and the nature of
the load. So, characterization is required to correlate the average
current to the solenoid opening.
For example, the PWM ratio must be increased when the solenoid
is frst energized to overcome static friction. Once static friction
is overcome, a different PWM relationship is used to move it in
and out.
Measuring the Current Through the Coil
The current is thus an important indication of the solenoids state.
The most effective method of measuring the solenoid current is
to measure the voltage across a resistive shunt connected in series
with the solenoid, the battery, and the switch. There are several
different ways to confgure this series circuit for switching and
voltage measurement.
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2 Analog Dialogue 38-04, April (2004)
Low-Side Current Sense with High-Side Drive
The circuit in Figure 1 shows a switch, connected to the high
(ungrounded) side of the battery, in series with the solenoid coil and
the grounded resistive shunt. A reversed diode is connected across
the coil to clamp (i.e., short-circuit) the inductive voltage generated
by the coil when the current is turned off. Using a ground reference
for the shunt allows an inexpensive op ampwith indifferent
common-mode specifcationsto be used in the electronic control
unit (ECU) to measure the voltage across the shunt.
V SHUNT* GAIN
SHUNT
SHORTTO
GROUND
CURRENT
DOES NOT
FLOW
THROUGH
SHUNT
HIGH-SIDE DRIVE/LOW-SIDE SENSE
LOWER COST AMPLIFIER
HIGHER COST SWITCH
HIGHER COST DRIVE FOR SWITCH
SHORT-CIRCUIT CURRENT DOES NOT FLOWTHROUGH SHUNT WHICH DOES NOT
ALLOW FOR DIAGNOSTICS OF SHORTTO GROUND (SHOWN OUTSIDETHE ECU), OR
SOLENOID CONDITION POTENTIALLY DAMAGINGWIRING ANDTHE SWITCH.
SWITCH
** **
** **
**POTENTIAL
SHORTS TO GROUND
SOLENOID
INDUCTIVE
LOAD
CLAMP
DIODE
RECIRCULATION
CURRENT
BATTERY
PWM
Figure 1. Electronic control unit with high-side switching
and low-side sensing.
When considering this approach, the designer must take into
account these disadvantages:
1. The solenoid recirculating current is not included in the
measurement, so this circuit provides an inaccurate measure
of the average current through the solenoid coil. The solenoid
recirculation current can be an aid to detecting solenoid
health; if some of the windings have begun to short, the
condition can be seen by measuring the passively controlled
recirculation current.
2. Because the switch is on the high side, it is more expensive
to buy and to drive. The PWM drive requires careful level
translation between the logic output of the microcontroller
and the gate.
3. Additional circuitry is needed to detect shorts to ground
because the short-circuit currents do not fow through the
shunt. Damage to the wiring and the FET can occur if shorts
to ground (Figure 1) are not detected.
4. The measurement may be unstable because, in practice, ground
is not the ideal universal connection, graphically rendered as
a little inverted triangle. In the actual application, ground
may not in fact be ground. Voltage drops caused by currents
between the op-amps ground and the shunt ground can cause
signifcant errors.
High-Side Current Sensing with a Low-Side Switch
A better method of driving the solenoid is to use a switch that
is referenced to ground (Figure 2), allowing the use of a less
expensive, low-side switch.
Signifcantly better diagnostics are possible because the solenoid
recirculation current is included in the measurement. In addition,
the drive is less expensive, because it is not necessary to perform
level translation to the gate.
LOW-SIDE
SWITCH
LOW-SIDE DRIVE/HIGH-SIDE SENSE
LOWER COST SWITCH
LOWER COST DRIVE FOR SWITCH BECAUSETHE GATE IS GROUND REFERENCED
NEEDTO USE A DIFFERENTIAL AMPLIFIERWITH COMMON-MODE RANGETHAT
EXTENDS ABOVETHE BATTERY
ALLOWS DIAGNOSTICS AND PROTECTION FOR SHORTSTO GROUND
**
**
**POTENTIAL
SHORTS TO GROUND
SOLENOID
CLAMP
DIODE
RECIRCULATION
CURRENT
14V
BATTERY
4-TERM
SHUNT
AMPLIFIERWITH HIGH
COMMON-MODE RANGE
SHORTTO GROUND
CURRENT FLOWS
THROUGH SHUNT
**
Figure 2. Electronic control unit with low-side switching
and high-side sensing.
However, the amplifer must have high, common-mode rejection,
and it must be able to stand off signifcant common-mode voltage
(CMV). The voltage level at the shunt in this example varies
from battery voltage to battery-voltage-plus-a- diode- drop.
Heres the explanation: When the switch is closed, the common-
mode voltage level at the shunt remains at the low impedance
battery voltage. When the switch is opened, the voltage across
the solenoid reverses because of the solenoids inductance, and
causes the common-mode voltage level to include the clamping
diode dropwhile the transient current fowsbefore settling
to the battery voltage.
An important beneft of this drive method is that it allows detection
of shorts to ground, because the high-side current fows through
the shuntas seen in Figure 2.
A key concern when using this current sensing method is that
the high side of the battery is always connected to the solenoid.
This could allow the solenoid to switch unexpectedly if there is an
intermittent short to ground. Also, the continuous presence of the
voltage at the solenoid could cause excessive corrosion over time.
High-Side Current Sensing with a High-Side Switch
A confguration that minimizes the possibility of unexpected
solenoid activation and excessive corrosion is shown in Figure 3,
where both the switch and the shunt are connected on the high
side. This removes the battery voltage from the solenoid when
the switch is off, preventing damage from potential shorts to
ground, and allows the recirculating current to be included in
the measurement. The battery voltage is removed from the load
when the switch is open, so corrosive effects caused by the voltage
differential are eliminated.
Analog Dialogue 38-04, April (2004) 3
HIGH-SIDE DRIVE
BATTERYVOLTAGE NOT CONNECTEDTO LOADWHEN SWITCH IS OFF WHICH
REDUCES CORROSION (SIGNIFICANT IN COMMERCIAL OR 42V SYSTEMS)
LOAD CAN BETIEDTO GROUND
REQUIRES AMPLIFIER COMMON-MODE RANGETO EXTEND BELOW GROUND
BECAUSE OF INDUCTORVOLTAGE REVERSAL
ALLOWS DIAGNOSTICS AND PROTECTION FOR SHORTSTO GROUND
CLAMP
DIODE
14V
BATTERY
RECIRCULATION
CURRENT
**
**
**POTENTIAL
SHORTS TO GROUND
HIGH-SIDE
SWITCH
4-TERM
SHUNT
AMPLIFIERWITH HIGH
COMMON-MODE RANGE
THAT CAN EXTEND
BELOW GROUND
SHORTTO GROUND
CURRENT FLOWS
THROUGH SHUNT AND
CAN DE DETECTED
**
Figure 3. Electronic control unit with low-side solenoid
and high-side switching and sensing.
In this case, however, the voltage reversal across the solenoid when
the switch is opened will cause a much wider swing of common-
mode voltage, from battery high-side voltage to one diode drop
below ground (the reverse voltage is limited by the clamping
diode). The amplifer used in this application must thus be able
to provide accurate measurement of the shunt voltage (current),
ignoring the large, rapid swing of common-mode voltage when
the switch goes off.
As with the low-side switching, high-side sensing confguration
(Figure 2), it is possible to measure shorts to ground, because all
of the solenoid current from the high side fows through the shunt,
as seen in Figure 3.
A Simple High-Side Current Measurement Circuit
Fortunately, the AD8200 single-supply difference amplifer, with
all the desirable properties for this applicationcomplete in a single
IC packageis available from Analog Devices. Figure 4 shows an
example of the AD8200 applied in an ECU to measure current
on the high side in this type of application. Here, the AD8200 is
used to amplify and flter the small, differential voltage from the
shunt, while rejecting the large common-mode swings mentioned
above. The AD8200 can be used in any of the confgurations
shown earlier.
** **
**
**POTENTIAL
SHORTS TO GROUND
NC = NO CONNECT
AD8200
OUT
+V
S
5V
NC
+IN
A2
A1
GND
IN
CLAMP
DIODE
14V
BATTERY
POWER
DEVICE
SHUNT
SOLENOID
EXTERNAL FILTER
CAPACITOR IS USED
TO FILTER HIGH
FREQUENCY NOISE
AND FINDTHE
AVERAGE CURRENT
THROUGHTHE
SOLENOID
**
Figure 4. Electronic control unit, using the AD8200, with
low-side solenoid and high-side switching and sensing.
The AD8200 uses a single +5 V supply and has an input common-
mode voltage range extending from 2 V to +24 V, with load
dump to +44 V. If higher common-mode range is required, use
of another member of the AD8200 family is recommendedfor
example, the AD8205, with a CMV range of 2 V to +65 V and
a gain of 50; or the AD8206 with a CMV range of 2 V to +65 V
and a gain of 20 (the same gain as the AD8200).
A2 OUT
RF
RF
A1
+IN
RA
IN
RA
RC RC
RB RB
100k
(TRIMMED)
COM
AD8200
TRIMMED RESISTOR
USEDWHEN FILTERING
IS REQUIRED
A3
R
CM
R
CM
RG RG
Figure 5. Functional block diagram of the AD8200.
Figure 5 is a functional block diagram of the internal wiring of
the AD8200. Before designing a differential amplifer using an
inexpensive op-amp and some external resistors, consider that
achieving the performance required to measure solenoid current
accurately enough for a control application requires a circuit built
with resistors that are precisely matched to within 0.01%. The
AD8200 has internal laser-trimmed resistors that allow for this
level of precise operation when handling both ac and dc voltages.
Typical offset- and gain drift in the SOIC package are 6 V/ C and
10 ppm/ C, respectively. The device also provides a minimum,
common-mode rejection of 80 dB from dc to 10 kHz.
Besides its availability in the SOIC package, the AD8200 is also
available in die form. Both package options are specifed over wide
temperature ranges, making the AD8200 well suited for use in
many automotive and industrial platforms. The SOIC package
is specifed for 40C to +125C and the die is specifed from
40C to +150C.
The AD8200 also features an externally accessible 100-k resistor
at the output of the preamplifer, which can be used with external
capacitance for low-pass flter applications, and with external
resistors for establishing gains other than the preset gain of 20.
APPENDIX
Mechanical Transmission Control
The older method of controlling transmission shift points involved
complex, speed-dependent hydraulic circuits. Shifting was done
through the use of changes in hydraulic pressure in a complex
valve body. The hydraulic pressure was modulated by a governor
attached to the output shaft. Centrifugal force moved the governor,
releasing transmission oil and increasing the pressure in the valve
body. The method of adapting to changing driving conditions
typically consisted of forcing the transmission to downshift under
heavy acceleration or loading with mechanical actuators.
When the driver needed more acceleration, the requirement was
typically transmitted via a down-shift mechanism, consisting of a
rod running from the throttle control in the engine compartment
to the side of the transmission. The rod moved a lever, closing off a
series of channels in the throttle body. This forced the transmission
to downshift under heavy acceleration until, at speed, the governor
overrode the down-shift mechanism.
Adapting to changes in load was accomplished using a vacuum
modulator. With increasing load on the engine, the vacuum change
caused a rod to slide in or out of the valve body, changing the
transmission shift point and shift speed. While these methods of
controlling shift points and shift smoothness worked, there was
little that could be done to adjust these parameters to more variable
conditions because of the characteristics of the mechanical system
used to control them. b