Proportional solenoid with magnetic circuit breaker structure stopper and armature assembly therein

Abstract

The present application relates to a kind of proportional electromagnet, to solve the difficulty of existing proportional electromagnet component processing manufacture, pollution resistance is not high and the low magnetic energy utilization rate of the shortcoming, the present application provides a proportional electromagnet with magnetic circuit breaker structure baffle, cover plate is connected with yoke right end integrally.Cover plate is provided with the contact ring of multiple non-continuous circular-arc convex structure.Gap and large hole are sequentially arranged in the inside of baffle from left to right.Bore is provided with the magnetic shunt of the cross section shape of triangular, semicircular or rectangular in cylinder section.Magnetic circuit breaker surrounds the circumference direction of cylinder section one round.Arrangement is arranged in the large hole of baffle.Joint right end can be contacted with contact ring.The surface of top rod is provided with the groove for connecting the small hole of baffle and the through hole of armature.Thin film is arranged between armature and the large hole of baffle, and armature can slide in thin film.Left magnetic circuit board is connected with baffle left end, right magnetic circuit board is connected with baffle right end.Coil is sleeved on baffle, and located in yoke interior.

Description

Technical Field

[0001] This invention patent relates to a proportional electromagnet, especially a proportional electromagnet used in various proportional solenoid valves and the structural stop iron of a magnetic circuit breaker that directly outputs electromagnetic force. Background Technology

[0002] The proportional electromagnet is a key driving component of a proportional solenoid valve. It is named for its near-linear, one-to-one correspondence between the output electromagnetic force and the input electrical signal. Proportional electromagnets exhibit excellent linearity over a wide stroke range and have low noise. They are widely used in various types of proportional solenoid valves and also serve as standalone driving elements to output electromagnetic force to drive other mechanical structures to achieve actions under electronic control signals.

[0003] Traditional proportional electromagnets are based on the theory of magnetic field lines and a magnetic shunt structure. They employ a stop with a magnetic shunt structure, along with pole shoes and an armature, to distribute the electromagnetic field within the electromagnet. This ensures that the electromagnetic force remains essentially constant when the distance between the armature and the stop (i.e., the armature's stroke) varies and the coil current is constant. Consequently, the electromagnetic force output by the electromagnet through the armature is primarily proportional to the equivalent current generated in the coil by the input signal. Proportional electromagnets based on the theory of magnetic field lines and a magnetic shunt structure place high demands on manufacturing. This is reflected in the need for good concentricity between the armature's axis and the axes of the pole shoes and the stop during armature movement. Due to manufacturing errors, the armature, which outputs electromagnetic force, must be provided with a material with a low coefficient of friction to support its reciprocating motion. Because friction materials are needed to support the armature's reciprocating motion, a large gap must be provided between the armature, the stop, and the pole shoes to allow for the installation of parts made of friction material. From the perspective of reluctance theory, the gaps left for the friction material create a large "equivalent magnetic reluctance" within the proportional electromagnet, significantly reducing the utilization rate of the magnetic field. In hydraulic proportional solenoid valves, such friction materials are often contaminated by the working medium, causing the electromagnet to become inflexible and leading to the failure of the proportional solenoid valve.

[0004] The structure represented by publication number "CN103050217B" fully embodies the theory of magnetic field lines and the structure of a magnetic shunt, possessing the core structural features of a typical magnetic shunt, including a stop, armature, and pole shoes. The double-support structure in this patent effectively solves the problem of friction pairs required for the reciprocating motion of the armature; however, it still places high demands on product manufacturing, resulting in difficulties in component processing and high assembly requirements, leading to inconsistent mass production quality. Furthermore, due to structural limitations, the gaps between the armature and the stop, as well as the gaps between the armature and the pole shoes, also exhibit relatively high equivalent magnetic reluctance, resulting in low utilization of the magnetic energy generated by the input signal excitation coil.

[0005] Publication number "CN103714940B" represents another type of magnetic field line theory and magnetic shunt structure. Its use of a connecting ring to integrate the stop and pole shoes effectively reduces manufacturing difficulty and allows for a smaller fit gap between the armature, stop, and pole shoes, reducing some of the equivalent magnetic reluctance. However, the through-hole structure of the stop, used to reduce manufacturing difficulty, increases the overall magnetic reluctance of the electromagnet, resulting in low utilization of the magnetic field energy generated by the input electrical signal excitation coil in proportional electromagnets. Furthermore, because the armature is not supported by other parts and directly contacts the stop and pole shoes to form a friction pair with a small fit gap, contaminants can enter the friction pair, causing the armature to move inflexibly; this structure has low resistance to contamination. In the patent with publication number "CN1272553C," the structure of a friction pair formed by a thin-walled stainless steel cylinder and the armature is a typical proportional electromagnet structure, also suffering from the increased equivalent magnetic reluctance caused by the thin-walled stainless steel cylinder. Additionally, the thin-walled stainless steel cylinder itself presents significant manufacturing challenges, leading to quality instability issues.

[0006] The patent with publication number "CN208750114U" describes a V-groove guide sleeve structure based on traditional magnetic field line theory. This achieves a near-constant "horizontal" characteristic where the electromagnetic force remains essentially constant despite changes in the stroke of a proportional electromagnet. However, its magnetic energy utilization rate is low, and the "horizontal" characteristic of the proportional electromagnet is inferior to that of the aforementioned patents. It remains a structure based on traditional magnetic field line theory. In particular, the method of using heat treatment on the guide sleeve to reduce the low magnetic energy utilization rate caused by "magnetic leakage" in the V-shaped structure can lead to large variations and poor consistency in mass-produced products in practical engineering.

[0007] Overall, due to insufficient in-depth research on basic theories, domestic proportional electromagnets have not yet broken through the limitations of basic theories, and have not completely solved the problems of high difficulty in processing and manufacturing parts, unstable mass production quality, and low efficiency in magnetic energy utilization. Summary of the Invention

[0008] To address the shortcomings of existing proportional electromagnets, such as high difficulty in manufacturing components, high requirements for product assembly, low resistance to contamination, and low magnetic energy utilization, this invention provides a proportional electromagnet with a magnetic circuit breaker structure stop iron and its armature component, which is based on fundamental theoretical research results, has lower component manufacturing difficulty, simpler product assembly, and higher magnetic energy utilization efficiency.

[0009] The technical solution of this invention:

[0010] The first type of proportional electromagnet with a magnetic circuit breaker-structured stop iron is characterized by comprising a left magnetic circuit plate 1, a yoke 2, a push rod 4, an armature 5, a right magnetic circuit plate 6, a cover plate 7, a thin film 8, a stop iron 9, and a coil 10; the yoke 2 is a cylindrical structure; the cover plate 7 is integrally connected to the right end of the yoke 2; the cover plate 7 is a circular plate structure with multiple segments of non-continuous arc-shaped protrusions forming contact rings 71; the stop iron 9 has a small hole 94 and a large hole 95 connected from left to right inside, and a connected left conical surface 91, a cylindrical section 92, and a right conical surface 93 outside; the cylindrical section 92 is a grooved structure with grooves having a triangular, semi-circular, or other cross-sectional shapes. A rectangular magnetic circuit breaker 92a surrounds the circumference of a cylindrical section 92. An armature 5 is disposed within a large hole 95 in a stop 9. The right end of the armature 5 can contact a contact ring 71. A groove is provided on the surface of a push rod 4 to connect a small hole 94 in the stop 9 and a through hole in the armature 5. The push rod 4 and the armature 5 are connected as a single unit. A diaphragm 8 is disposed between the armature 5 and the large hole 95 in the stop 9, and the armature 5 can slide within the diaphragm 8. Both the left magnetic circuit plate 1 and the right magnetic circuit plate 6 are annular structures, with the left magnetic circuit plate 1 connected to the left end of the stop 9 and the right magnetic circuit plate 6 connected to the right end of the stop 9. A coil 10 is fitted onto the stop 9 and located inside the yoke 2.

[0011] The aforementioned proportional electromagnet also includes a shim 3; the shim 3 is a thin circular ring structure made of non-magnetic material; the shim 3 is located at the connection between the large hole 95 and the small hole 94 of the stop 9, and is close to the left end of the large hole 95. The aforementioned magnetic circuit breaker 92a can be wound in a circular ring, a single spiral, multiple spirals, or multiple discontinuous arcs; when the magnetic circuit breaker 92a is wound in a single spiral, the helix angle is along the axial direction of the cylindrical segment 92; when the magnetic circuit breaker 92a is wound in multiple spirals, each spiral is evenly distributed radially along the cylindrical segment 92, and the helix angle is along the axial direction of the cylindrical segment 92; when the magnetic circuit breaker 92a is wound in multiple discontinuous arcs, each arc segment is arranged sequentially along the axis of the cylindrical segment 92 and encircles the circumference of the cylindrical segment 92 more than once.

[0012] The aforementioned film is made of a high-temperature resistant plastic material with a low coefficient of friction, and its thickness is between 0.02 and 0.15 mm. Alternatively, the film can be made of polytetrafluoroethylene (PTFE), with a thickness between 0.02 and 0.15 mm.

[0013] The second type of proportional electromagnet with a magnetic circuit breaker structure and a stop iron is characterized by comprising a left magnetic circuit plate 1, a yoke 2, a top rod 4, an armature 5, a right magnetic circuit plate 6, a cover plate 7, a stop iron 9, and a coil 10; the yoke 2 is a cylindrical structure; the cover plate 7 is integrally connected to the right end of the yoke 2; the cover plate 7 is a circular plate structure with multiple segments of non-continuous arc-shaped protrusions forming contact rings 71; the stop iron 9 has interconnected small holes 94 and large holes 95 inside from left to right, and interconnected left conical surface 91, cylindrical section 92, and right conical surface 93 outside; the cylindrical section 92 is a grooved structure with a magnetic circuit breaker 92a having a groove cross-sectional shape of triangle, semicircle, or rectangle; the magnetic circuit breaker 92a surrounds the circular... The column segment 92 is circumferentially circumferential; the armature 5 is set in the large hole 95 of the stop 9; the right end of the armature 5 can contact the contact ring 71; the armature 5 is provided with an even number of cavities 11, each cavity is inlaid with a ball 11a; part of the spherical surface of each ball 11a is exposed on the cylindrical surface of the armature 5, and the ball 11a can reciprocate within the large hole 95 of the stop 9; the surface of the push rod 4 is provided with a groove for connecting the small hole 94 of the stop 9 and the through hole in the armature 5; the push rod 4 and the armature 5 are connected as one unit; the left magnetic circuit plate 1 and the right magnetic circuit plate 6 are both annular structures, and the left magnetic circuit plate 1 is connected to the left end of the stop 9, and the right magnetic circuit plate 6 is connected to the right end of the stop 9; the coil 10 is sleeved on the stop 9 and is located inside the yoke 2.

[0014] The aforementioned proportional electromagnet also includes a shim 3; the shim 3 is a thin circular ring structure made of non-magnetic material; the shim 3 is located at the connection between the large hole 95 and the small hole 94 of the stop 9, and is close to the left end of the large hole 95. The aforementioned magnetic circuit breaker 92a can be wound in a circular ring, a single spiral, multiple spirals, or multiple discontinuous arcs; when the magnetic circuit breaker 92a is wound in a single spiral, the helix angle is along the axial direction of the cylindrical segment 92; when the magnetic circuit breaker 92a is wound in multiple spirals, each spiral is evenly distributed radially along the cylindrical segment 92, and the helix angle is along the axial direction of the cylindrical segment 92; when the magnetic circuit breaker 92a is wound in multiple discontinuous arcs, each arc segment is arranged sequentially along the axis of the cylindrical segment 92 and encircles the circumference of the cylindrical segment 92 more than once.

[0015] The present invention also provides an armature component with ball bearings, wherein the armature component with ball bearings is composed of an armature 5 and a ball bearing 11; the left end of the outer cylindrical surface of the armature 1 is provided with a cavity 11a with a spherical bottom and the right end is provided with a cavity 11a with a spherical bottom; the ball bearing 11 is spherical; the ball bearing 11 is placed in the cavity 11a provided on the armature.

[0016] The dimension A of the ball bearing 11 protruding above the cylindrical surface of the armature 5 is between 0.01 and 0.2 mm; the cavities 11a at the left and right ends of the armature 5 are distributed in a straight line along the armature axis; the number of cavities 11a at the left end of the cylindrical surface of the armature 5 is even, and the number of cavities 11a at the right end of the cylindrical surface is even.

[0017] Advantages of this invention:

[0018] 1. This invention uses a stop iron with a segmented arc or spiral groove structure magnetic circuit breaker with a triangular, arc or rectangular cross-section, which realizes the integrated design of the stop iron and the pole shoe, effectively increasing the magnetic resistance of the stop iron along the axis of the electromagnet and reducing the magnetic energy loss caused by the magnetic field directly forming a loop along the stop iron.

[0019] 2. The first proportional electromagnet of this invention uses a friction pair composed of a thin film and an armature component, which has the advantages of a low coefficient of friction and minimal impact of friction on the electromagnet's performance. This invention, using a friction pair composed of a thin film and an armature, has a small axial gap between the stop and the armature, reducing the equivalent magnetic reluctance and improving the proportional electromagnet's efficiency in utilizing magnetic energy. Furthermore, this invention, using a friction pair composed of a thin film and an armature, simplifies the product assembly process and results in a high product qualification rate.

[0020] 3. The second type of proportional electromagnet of the present invention adopts a combination of a stop iron and an armature component with ball bearings to realize a proportional electromagnet structure with a conventional combination of stop iron, armature and pole shoe. The proportional electromagnet has high linearity of output electromagnetic force, low hysteresis and excellent performance.

[0021] 4. The second type of proportional electromagnet of this invention uses ball bearings as the moving friction component, realizing a change in the armature's working mode from the previous sliding mode to a rolling mode. Friction is almost negligible, and it has an exceptionally long service life. The use of ball bearings as the moving friction component results in a very small clearance between the inner hole of the stop and the armature components, effectively reducing magnetic field energy loss caused by magnetic lines of force passing through the non-magnetic air gap between the stop and the armature. The use of ball bearings as the moving friction component reduces the impact of contaminants due to the rolling motion itself, and the existence of a gap between the ball bearings and the inner hole of the stop also provides a deposition area for contaminants, reducing the potential for electromagnet failure due to contaminant deposition.

[0022] 5. This invention patent adopts an integrated stop with a magnetic circuit breaker structure, which significantly reduces the processing difficulty of the stop and can significantly reduce the impact of part damage caused by transportation and other processes on product performance, and can also significantly reduce product costs.

[0023] 6. The armature component of this invention uses freely rotatable balls embedded inside the armature to achieve rolling friction between the moving armature and the mating parts. This results in a low coefficient of friction, less armature wear, and a long service life. At the same time, the moving armature and the mating parts form a rolling friction pair, which has good anti-pollution ability. Attached Figure Description

[0024] Figure 1 This is a schematic diagram illustrating the structural principle of the first proportional electromagnet with a magnetic circuit breaker-structured stop iron according to the present invention.

[0025] Figure 2 This is a schematic diagram illustrating the working principle of the proportional electromagnet with a magnetic circuit breaker structure stop iron of the present invention.

[0026] Figure 3 This is a schematic diagram of a proportional electromagnet with a magnetic circuit breaker structure stop iron, where the magnetic circuit breaker is a single helical shape.

[0027] Figure 4 This is a schematic diagram of a proportional electromagnet with a magnetic circuit breaker structure stop iron, where the magnetic circuit breaker is a multi-helix shape.

[0028] Figure 5 This is a schematic diagram of the proportional electromagnet with a magnetic circuit breaker structure stop iron of the present invention, in which the magnetic circuit breaker is multi-segmented arc-shaped;

[0029] Figure 6 This is a schematic diagram of the structural principle of the second type of proportional electromagnet with a magnetic circuit breaker structure stop iron according to the present invention;

[0030] Figure 7 yes Figure 6 Schematic diagram of the armature component;

[0031] Figure 8 yes Figure 7 Enlarged view of part of the image;

[0032] Figure 9 yes Figure 7 A three-dimensional structural diagram of the armature component.

[0033] The attached diagram is labeled as follows: 1-Left magnetic circuit plate, 2-Yoke, 3-Shim, 4-Top rod, 5-Armature, 6-Right magnetic circuit plate, 7-Cover plate, 71-Contact ring, 8-Thin film, 9-Stop, 91-Left conical surface, 92-Cylindrical section, 92a-Magnetic circuit breaker, 92b-Helical structure, 92c-First helical structure, 92d-Second helical structure, 92e-First circular arc structure, 92f-Second circular arc structure, 93-Right conical surface, 94-Small hole, 95-Large hole, 10-Coil, 11-Ball, 11a-Cavity. Detailed Implementation

[0034] like Figure 1As shown, the first type of proportional electromagnet with a magnetic circuit breaker structure includes a left magnetic circuit plate 1, a yoke 2, a gasket 3, a top rod 4, an armature 5, a right magnetic circuit plate 6, a cover plate 7, a thin film 8, a stop 9 with a magnetic circuit breaker 92a, and a coil 10.

[0035] Both the left magnetic circuit plate 1 and the right magnetic circuit plate 6 are annular structures made of soft magnetic material, used to form the magnetic field loop inside the proportional electromagnet. The yoke 2 is a cylindrical structure made of soft magnetic material, used to form the magnetic field loop of the proportional electromagnet, and also used to mount and position the left magnetic circuit plate 1, right magnetic circuit plate 6, cover plate 7, and coil 10. The gasket 3 is a thin annular structure made of non-magnetic material, used to prevent excessive residual magnetism in the electromagnet caused by the left end face of the armature 5 contacting the bottom of the large hole 95 inside the stop 9 when the electromagnet is attracted. The push rod 4 is a cylindrical structure made of non-magnetic material, with grooves on its surface to connect the small hole 94 inside the stop 9 and the through hole inside the armature 5. The armature 5 is a cylindrical structure with an internal through hole, made of soft magnetic material; the push rod 4 and the armature 5 are riveted together. The cover plate 7 is a thin, circular sheet structure made of non-magnetic material. It has a contact ring 71 with multiple discontinuous arc-shaped protrusions. The contact ring 71 is used to prevent the right end face of the armature 5 from sticking to the cover plate 7 when the proportional electromagnet is immersed in liquid, which would cause working resistance problems. When the armature 5 moves close to the cover plate 7, it only contacts the contact ring 71 composed of multiple protruding arc structures on the cover plate 7.

[0036] A thin film 8, with a thickness between 0.02 and 0.15 mm, is provided between the armature 5 and the stop 9. The film 8 can be rectangular, or cylindrical when placed inside the large hole 95 of the stop 9, and is made of polytetrafluoroethylene or other high-temperature resistant plastic material with a low coefficient of friction. The inner surface of the film 8 is fitted onto the outer cylindrical surface of the armature 5, and the outer surface is in close contact with the inner wall of the large hole 95 of the stop 9. The left end is in close contact with the left end of the large hole 95 of the stop 9, and the right end is in close contact with the cover plate 7. The armature 5 can slide within the film 8.

[0037] The stop 9 is a cylindrical structure with a small hole 94 at its left end and a large hole 95 at its right end, which are connected. It is made of soft magnetic material and has a connected left conical surface 91, a cylindrical section 92, and a right conical surface 93 on its exterior. The cylindrical section 92 has a grooved structure and a magnetic circuit breaker 92a with a triangular, semi-circular, or rectangular cross-sectional shape. The magnetic circuit breaker 92a surrounds the circumference of the cylindrical section 92 in a circular, helical, or multi-discontinuous arc configuration. When the surrounding shape consists of multiple discontinuous arcs, for example… Figure 5 The first circular arc structure 92e and the second circular arc structure 92f; each circular arc segment is arranged along the axis of the cylindrical segment 92. See also Figure 3When the magnetic circuit breaker 92a has a single helical structure 92b, the helix angle is along the axial direction of the cylindrical section 92; when the magnetic circuit breaker 92a has multiple helical structures, for example... Figure 4 The first helical structure 92c and the second helical structure 92d are in the middle; each helical line is evenly distributed radially along the cylindrical segment 92, and the helix angle of each helical line is along the axial direction of the cylindrical segment 92; when the magnetic circuit breaker 92a is surrounded by a multi-segment arc shape, each segment of the arc is arranged sequentially along the axial direction of the cylindrical segment 92 and surrounds the circumference of the cylindrical segment 92 more than once.

[0038] The left magnetic circuit plate 1 is tightly connected to the left end of the stop 9. The left end of the left magnetic circuit plate 1 is used to install and connect the main valve or other mechanical components.

[0039] The coil 10 is composed of plastic, enameled wire, and copper electrical pins. It is used to receive drive electrical signals to generate a magnetic field that drives the armature 5 to output electromagnetic force outward through the push rod 4. The coil 10 is sleeved on the outer circle of the stop 9, located inside the yoke 2, with its left end close to the left magnetic circuit plate 1 and its right end close to the right magnetic circuit plate 6.

[0040] The yoke 2 is riveted to the cover plate 7 as a whole and is used for the installation and positioning of the left magnetic circuit plate 1, the gasket 3, the armature 5, the right magnetic circuit plate 6, the stop 8 and the coil 9.

[0041] The gasket 3 is placed at the connection between the large hole 95 and the small hole 94 inside the stop 9, and is pressed tightly against the bottom of the large hole 95.

[0042] The push rod 4 and the armature 5 are tightly connected as one unit. The right end of the stop 9 is tightly connected to the right magnetic circuit plate 6. The armature 5 is placed inside the large hole 95 inside the stop 9, and the armature 5 can slide inside the large hole 95 inside the stop 9.

[0043] Figure 2 This is a schematic diagram of the working principle of a proportional electromagnet with a magnetic circuit breaker-like stop iron. The arrows in the diagram represent simulated magnetic lines of force.

[0044] When the coil is energized and generates a magnetic field, the magnetic lines of force form a closed magnetic field loop via the yoke 2, left magnetic circuit plate 1, right magnetic circuit plate 6, armature 5, and stop 9. Since the soft magnetic material itself also possesses magnetic reluctance, the magnetic lines of force, while avoiding congestion of magnetic field particles, together with the bottom of the left conical surface 91, cylindrical section 92, and right conical surface 93 on the stop 9, as well as the large hole 95 inside, form a magnetic circuit breaker structure with the armature 5, thus forming the core structural features of the proportional electromagnet. Because the left conical surface 91, cylindrical section 92, and right conical surface 93 on the stop 9 are made of the same soft magnetic material and have low magnetic reluctance, the magnetic lines of force are relatively densely distributed along these surfaces. However, since these magnetic lines of force do not pass through the armature 5, they cannot act on the armature 5 to generate the electromagnetic force output by the electromagnet during operation, resulting in a reduction in the utilization rate of the magnetic field capability. Reducing the wall thickness of the cylindrical section 92 on the stop block 9 can effectively improve the magnetic energy utilization rate, but an excessively thin wall thickness will cause the stop block 9 to be subject to collision deformation and thermal deformation due to the lack of necessary structural strength.

[0045] The magnetic circuit breaker 92a has a structure in which a cylindrical section 92 with a certain wall thickness has a groove with a triangular, rectangular, or arc-shaped cross-section. This groove encircles the cylindrical surface of the cylindrical section 92 and is spirally distributed along the axis of the stop 9. Alternatively, it can be composed of multiple spirally distributed grooves along the cylindrical section 92 and the axis of the stop 9, or multiple grooves parallel to the cross-section of the cylindrical section 92 and distributed along the axis of the annular groove stop 9. Since the magnetic field lines are smooth vector curves (i.e., the trajectory of magnetic field particles is a vector), forming a closed loop along the left conical surface 91, the cylindrical section 92, and the right conical surface 93, when passing through the groove structure of the magnetic circuit breaker 92a, the magnetic field lines cannot form a loop along the edge of the cross-section of the groove, and thus can only continue to advance along the tangential direction at the bottom of the groove. Magnetic field particle eddies are formed at the bottom of the groove of the magnetic circuit breaker 92a, thus creating a large magnetic reluctance. Because magnetic field lines have the characteristic of forming a loop with minimum magnetic resistance (considering magnetic resistance caused by magnetic field particle congestion), the closed magnetic field line loop formed along the left conical surface 91, the cylindrical segment 92 and the right conical surface 93 is significantly reduced, forcing the magnetic field lines to pass through the armature 5 to form a loop, thus becoming a proportional electromagnet that generates electromagnetic attraction through the armature 5 and then outputs electromagnetic force outward through the push rod 4 connected to the armature 5.

[0046] Due to the presence of the magnetic shunt and magnetic circuit breaker structures, when the electrical signal input to coil 10 remains constant, the electromagnetic attraction force on armature 5 remains relatively stable regardless of the change in distance between armature 5 and the bottom of the large hole 95 in stop 9. Therefore, it can be simplified to consider that the electromagnetic force output by the electromagnet is only proportional to the magnitude of the input electrical signal, forming the linear output characteristic of a proportional electromagnet.

[0047] like Figure 6 As shown, the second type of proportional electromagnet with a magnetic circuit breaker structure stop iron of the present invention differs from the first type of electromagnet mainly in its armature component. In the armature component of the second type of proportional electromagnet, a thin film is no longer used; instead, an even number of balls are embedded in the armature. See [link to previous section]. Figures 7 to 9 This design changes the traditional reciprocating motion between the armature and the stop, which relies on relative sliding, to a rolling contact between the ball bearings and both the armature and the stop, thus significantly reducing frictional resistance. Simultaneously, the ball bearings support the armature and create a reasonable gap with the large hole in the stop. This avoids the problem of high magnetic resistance and low magnetic energy utilization caused by excessively large gaps, while also providing ample space to accommodate contaminants entering the electromagnet, improving its anti-contamination performance.

[0048] Practical applications show that the two proportional electromagnets of this invention have high magnetic energy utilization efficiency (i.e., larger output electromagnetic force under the same input power), good anti-pollution properties, easy parts processing, good batch manufacturing stability, and can be widely used in various proportional solenoid valves and direct drive mechanical mechanisms.

[0049] For this proportional electromagnet, the output force F I The relationship between it and the current I is:

[0050] F I =K I ×I

[0051] Among them, F I —Electromagnetic attraction (varies with current);

[0052] I – Current value (controllable input quantity);

[0053] K I —Proportionality coefficient (a constant value once the structure is determined).

[0054] In addition, the present invention also provides an armature component applicable to a second type of proportional electromagnet, see [link to relevant documentation]. Figures 7 to 9 It consists of armature 5 and ball bearings 11.

[0055] The left and right ends of the outer cylindrical surface of the armature are respectively provided with cavities 11a, specifically blind hole-shaped ball sockets with a spherical bottom. The ball 11 is spherical and made of non-soft magnetic material.

[0056] The armature has an even number of ball sockets on both the left and right ends of its cylindrical surface. Each ball is placed in one of these sockets. The ball sockets on the left and right ends of the armature are arranged in a straight line along the armature's axis. The bottom of each ball socket on the armature is nearly hemispherical. The balls are installed in these sockets and can roll freely. The distance A of the ball protruding above the cylindrical surface of the armature is between 0.01 and 0.2 mm.

[0057] When a magnetic field acts on the armature component, the armature moves under the attraction of the magnetic field. The armature and support are connected and supported by ball bearings. Since the ball bearings can rotate freely within the armature, relative rolling occurs between the ball bearings and the armature, and also between the ball bearings and the support. The rolling friction force on the armature component is significantly lower than the sliding friction force in a conventional armature sliding friction pair structure. The armature uses a soft magnetic material that does not directly contact the support, and therefore does not wear when moving in the magnetic field. Under the same pressure, the wear from rolling friction is significantly less than that from sliding friction. The rolling friction structure between the soft magnetic material and the wear-resistant ball bearings results in significantly less wear than that of armatures using a typical sliding friction structure.

[0058] When the working environment of the armature component is contaminated, virtually no contaminants can enter the interlocking structure between the armature and the ball, preventing the ball from seizing and becoming unable to roll due to the accumulation of contaminants. As the ball supports the reciprocating motion of the armature, any contaminants present are squeezed out of the ball's trajectory by the rolling motion, achieving a self-cleaning function for the ball, thus exhibiting good anti-contamination capabilities.

[0059] Practical applications show that this armature component with ball bearings has good mobility and strong resistance to contamination, and is widely used in various proportional electromagnets.

Claims

1. A proportional electromagnet with a magnetic circuit breaker-structured stop iron, characterized in that: It includes a left magnetic circuit plate (1), a yoke (2), a push rod (4), an armature (5), a right magnetic circuit plate (6), a cover plate (7), a thin film (8), a stop (9), and a coil (10); The yoke (2) has a cylindrical structure; The cover plate (7) is connected to the right end of the yoke (2) as a whole; the cover plate (7) is a circular plate structure, and a contact ring (71) with multiple non-continuous arc-shaped protrusions is provided on it; The stop (9) has a small hole (94) and a large hole (95) connected from left to right inside, and a left conical surface (91), a cylindrical section (92) and a right conical surface (93) connected outside. The cylindrical section (92) is a grooved structure, and a magnetic circuit breaker (92a) with a groove cross-sectional shape of triangle, semi-circle or rectangle is provided on it. The magnetic circuit breaker (92a) surrounds the circumference of the cylindrical section (92). The armature (5) is disposed in the large hole (95) of the stop (9); the right end of the armature (5) is used to contact the contact ring (71); The surface of the top rod (4) is provided with a small hole (94) for connecting the stop (9) and a groove for the through hole in the armature (5); the top rod (4) and the armature (5) are connected as one piece; The thin film (8) is disposed between the armature (5) and the large hole (95) of the stop (9), and the armature (5) slides within the thin film (8); The left magnetic circuit plate (1) and the right magnetic circuit plate (6) are both ring-shaped structures. The left magnetic circuit plate (1) is connected to the left end of the stop iron (9), and the right magnetic circuit plate (6) is connected to the right end of the stop iron (9). The coil (10) is sleeved on the stop iron (9) and is located inside the yoke iron (2).

2. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 1, characterized in that: It also includes a gasket (3); the gasket (3) is a thin ring structure made of non-magnetic material; the gasket (3) is set at the connection between the large hole (95) and the small hole (94) of the stop (9) and is close to the left end of the large hole (95).

3. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 1 or 2, characterized in that: The magnetic circuit breaker (92a) can be wound in the form of a ring, a single spiral, multiple spirals, or multiple discontinuous arcs. When the magnetic circuit breaker (92a) has a single spiral shape, the direction of the spiral angle is along the axial direction of the cylindrical section (92); When the magnetic circuit breaker (92a) is surrounded by multiple spirals, each spiral is evenly distributed radially along the cylindrical section (92), and the helix angle of each spiral is along the axial direction of the cylindrical section (92); When the magnetic circuit breaker (92a) is surrounded by multiple discontinuous arcs, each arc segment is arranged sequentially along the axis of the cylindrical segment (92) and surrounds the circumference of the cylindrical segment (92) for more than one revolution.

4. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 3, characterized in that: The film (8) is made of a plastic material that is resistant to high temperature and has a low coefficient of friction, with a thickness between 0.02 and 0.15 mm.

5. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 3, characterized in that: The film (8) is polytetrafluoroethylene with a thickness between 0.02 and 0.15 mm.

6. A proportional electromagnet with a magnetic circuit breaker structure stop iron, characterized in that: It includes a left magnetic circuit plate (1), a yoke (2), a push rod (4), an armature (5), a right magnetic circuit plate (6), a cover plate (7), a stop (9), and a coil (10); The yoke (2) has a cylindrical structure; The cover plate (7) is connected to the right end of the yoke (2) as a whole; the cover plate (7) is a circular plate structure, and a contact ring (71) with multiple non-continuous arc-shaped protrusions is provided on it; The stop (9) has a small hole (94) and a large hole (95) connected from left to right inside, and a left conical surface (91), a cylindrical section (92) and a right conical surface (93) connected outside. The cylindrical section (92) is a grooved structure, and a magnetic circuit breaker (92a) with a groove cross-sectional shape of triangle, semi-circle or rectangle is provided on it. The magnetic circuit breaker (92a) surrounds the circumference of the cylindrical section (92). The armature (5) is set in the large hole (95) of the stop (9); the right end of the armature (5) is used to contact the contact ring (71); the armature (5) is provided with an even number of cavities (11), each cavity is inlaid with a ball (11a); part of the spherical surface of each ball (11a) is exposed on the cylindrical surface of the armature (5), and the ball (11a) reciprocates in the large hole (95) of the stop (9); The surface of the top rod (4) is provided with a small hole (94) for connecting the stop (9) and a groove for the through hole in the armature (5); the top rod (4) and the armature (5) are connected as one piece; The left magnetic circuit plate (1) and the right magnetic circuit plate (6) are both ring-shaped structures. The left magnetic circuit plate (1) is connected to the left end of the stop iron (9), and the right magnetic circuit plate (6) is connected to the right end of the stop iron (9). The coil (10) is sleeved on the stop iron (9) and is located inside the yoke iron (2).

7. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 6, characterized in that: It also includes a gasket (3); the gasket (3) is a thin ring structure made of non-magnetic material; the gasket (3) is set at the connection between the large hole (95) and the small hole (94) of the stop (9) and is close to the left end of the large hole (95).

8. The proportional electromagnet with a magnetic circuit breaker structure stop iron according to claim 6 or 7, characterized in that: The magnetic circuit breaker (92a) can be wound in the form of a ring, a single spiral, multiple spirals, or multiple discontinuous arcs. When the magnetic circuit breaker (92a) has a single spiral shape, the direction of the spiral angle is along the axial direction of the cylindrical section (92); When the magnetic circuit breaker (92a) is wound in the shape of multiple spirals, each spiral is evenly distributed radially along the cylindrical section (92), and the helix angle of each spiral is along the axial direction of the cylindrical section (92); When the magnetic circuit breaker (92a) is surrounded by multiple discontinuous arcs, each arc segment is arranged sequentially along the axis of the cylindrical segment (92) and surrounds the circumference of the cylindrical segment (92) for more than one revolution.

9. An armature component with ball bearings, characterized in that: The armature component with ball bearings consists of an armature (5) and ball bearings (11); The armature (5) has a cavity (11a) with a spherical bottom at the left end and a cavity (11a) with a spherical bottom at the right end on its outer cylindrical surface. The ball (11) is spherical; The ball (11) is placed in a cavity (11a) provided on the armature.

10. An armature component with ball bearings according to claim 9, characterized in that: The dimension A of the ball (11) protruding above the cylindrical surface of the armature (5) is between 0.01 and 0.2 mm; The cavities (11a) at the left and right ends of the armature (5) are distributed in a straight line along the armature axis. The armature (5) has an even number of cavities (11a) on the left end of its cylindrical surface and an even number of cavities (11a) on the right end of its cylindrical surface.

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