Smart Solenoid Driver with Predictive Maintenance Reference Design


Design files


This reference design is a solenoid driver that implements additional monitoring control as well as diagnostic features. These features enable for example: lose spring detection, valve aging recognition and dynamic control of solenoid current. This predictive maintenance feature-set helps to decrease or even eliminate factory downtime. Moreover, the control of the solenoid current supports energy saving and increased valve lifetime. The integrated IO-Link interface provides the possibility of communication between Programmable Logic Controller (PLC) and actuator to leverage the predictive maintenance feature-set. The switching of the solenoid is realized using the PWM output of the microcontroller (MCU) to drive the current of a FET, which then supplies the solenoid switching current. The current signature is sampled with the on-chip 12-bit ADC and stored in the on-chip FRAM. This reference design implements a moving average calculation and a calculation of extreme values of the current signature curve.

  • Solenoid driver:  based on MSP430™ PWM output; configurable PWM output for different drive currents
  • Current signature captured by integrated 12-bit ADC
    • Current signature can be stored in MSP430 FRAM
    • Single processing functions implemented in firmware:
    • Moving average
    • Detection of local extreme values
  • Configuration through UART or IO-link

Design files & products

Design files

Download ready-to-use system files to speed your design process.

TIDUCO6.PDF (1515 K)

Reference design overview and verified performance test data


Detailed schematic diagram for design layout and components


Complete listing of design components, reference designators, and manufacturers/part numbers


Detailed overview of design layout for component placement

TIDRRU0.ZIP (1192 K)

Files used for 3D models or 2D drawings of IC components


Design file that contains information on physical board layer of design PCB


PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

IO-Link & digital I/Os

TIOL111IO-Link device transceiver with integrated surge protection

Data sheet document-pdfAcrobat PDF open-in-new HTML
MSP430 microcontrollers

MSP430FR596916 MHz MCU with 64KB FRAM, 2KB SRAM, AES, 12-bit ADC, comparator, DMA, UART/SPI/I2C, timer

Data sheet document-pdfAcrobat PDF open-in-new HTML

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Support software

TIDA-01250 — TIDCDN2.ZIP (32 K)

Technical documentation

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Type Title Date
* Design guide Smart Solenoid Driver With Predictive Maintenance Reference Design Jul. 17, 2017
Technical article Is your factory smarter than a fifth grader? Sep. 28, 2017
More literature Liberate your solenoid or relay from the bonds of supply voltage Jul. 17, 2017
White paper Detection of Plunger Movement in DC Solenoids White Paper Jun. 12, 2015

Related design resources

Reference designs

TIDA-00284 Current Controlled Driver for 230V AC Solenoids Reference Design TIDA-00289 Current Controlled Driver for 24-V DC Solenoid with Plunger Fault Detection Reference Design

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