Electromagnetic Actuator Bearing Structure for Precise Positioning
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Solution Overview
Problem
Conventional electromagnetic actuators in automatic transmissions face challenges in handling large acceleration forces and maintaining precise positioning of the operating element within the hydraulic system, leading to potential damage and undesired flow issues due to limited mechanical linkage and production tolerances.
Innovation Solution
The electromagnetic actuator features a flux-directing part constructed in two parts, with the operating element mounted in separate bearing points on both parts, allowing for precise alignment and reduced bearing clearance, and includes a fastening groove for mechanical fastening onto the hydraulic system, enabling accurate positioning and high strength without laborious production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the flux-directing part is embodied in one piece, then the structure is simple, but the load-carrying capacity is limited and positioning precision is insufficient
Solution Approach 1:
The flux-directing part is divided into two separate components: a base element and a flux disk. This segmentation allows each component to be optimized independently - the base element provides structural strength and mounting functionality, while the flux disk provides precise positioning and magnetic flux guidance. The separation enables the mounting system to handle large acceleration forces without compromising positioning precision.
2Device complexity
If the operating element is mounted in a single bearing point, then the structure is simple, but the positioning precision and stability are insufficient
Solution Approach 1:
The single bearing point is segmented into two separate bearing points distributed on the flux-directing part. This distribution of bearing points provides better mechanical support, reduces radial runout, and improves the positioning stability of the operating element. The dual bearing point configuration allows for more accurate positioning relative to the hydraulic control system edges.
3Strength
If the flux-directing part is constructed in two parts, then the load-carrying capacity and positioning precision are improved, but the manufacturing complexity increases
Solution Approach 1:
Dividing the flux-directing part into two components enables independent manufacturing optimization. Each component can be manufactured using processes best suited to its specific requirements, and they can be assembled separately, potentially reducing overall manufacturing complexity despite the increased part count.
Solution Approach 2:
The flux disk is positioned within a recess of the base element, creating a nested configuration. This nesting arrangement allows the two components to be integrated into a compact assembly that occupies minimal space, and the recess provides precise positioning of the flux disk relative to the base element during assembly.
4Manufacturing precision
If the bearing clearance is large, then the manufacturing tolerances are easier to achieve, but foreign particles can enter the actuator
Solution Approach 1:
The bearing clearance is segmented into two separate clearance regions, one at each bearing point. This segmentation allows for optimized clearance control in each region, maintaining sufficiently small clearances to prevent foreign particle ingress while still accommodating reasonable manufacturing tolerances through the distributed bearing point configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the mechanical linkage's ability to handle high forces, reduces the risk of foreign particles entering the actuator, and ensures precise positioning, improving the sliding behavior and reliability of the actuator while maintaining geometric precision and strength.
Implementation Method 1
a magnetic coil, proceeding around the longitudinal axis, for generating a magnetic field in order to move the armature
Implementation Method 2
a flux disk element, disposed at an axial end of the magnetic coil, having a recess which extends in the direction of the longitudinal axis and in which the operating element is displaceably mounted. The magnetic flux disk element on the one hand serves to direct the magnetic flux.
Data Source
AI summary
An electromagnetic actuator. The electromagnetic armature includes: an armature movable in an axial direction in an armature space; a magnetic coil for generating a magnetic field to move the armature; an operating element motion-coupled to the armature; and a flux-directing part, disposed at an axial end of the magnetic coil, having a recess which extends in the axial direction and in which the operating element is displaceably disposed, the flux-directing part being embodied in two parts. The flux-directing part is embodiment in two parts from a base part facing toward the armature and a top part facing away from the armature. The operating element is mounted, displaceably in the axial direction, in a first bearing point embodied on the top part and in a second bearing point embodied on the base part.