Electromagnetic Actuator Bobbin with Frustoconical Magnet
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Solution Overview
Problem
Existing electromagnetic actuators face high manufacturing and assembly costs due to the need for complex components with tight tolerances, making them difficult and time-consuming to produce.
Innovation Solution
The design features a modular electromagnetic actuator with a bobbin and magnetic circuit components that allow for relaxed dimensional tolerances, using a non-magnetic housing and easily machineable materials, enabling simpler assembly and reduced costs through a columnar stacked arrangement of components with axial magnetic flux flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tight dimensional tolerances are used for machined components, then the holding force and component alignment are sufficient for proper actuator function, but manufacturing costs increase and assembly time increases
Solution Approach 1:
The patent changes the geometric parameters of the magnetic circuit components, specifically using a frustoconical shape for the permanent magnet rather than a cylindrical shape. This parameter change allows the magnetic flux to be concentrated in a specific pattern that maintains holding force while tolerating larger dimensional variations in other components, thereby reducing manufacturing costs
Solution Approach 2:
The patent applies local quality by creating a specific frustoconical region in the permanent magnet where the magnetic flux is concentrated. This localized geometric feature ensures proper component alignment and sufficient holding force only where needed, while other components can have relaxed tolerances, reducing overall manufacturing complexity and cost
2Reliability
If tight dimensional tolerances are used for machined components, then the holding force and component alignment are sufficient for proper actuator function, but assembly time increases
Solution Approach 1:
The frustoconical geometry of the permanent magnet creates a self-aligning feature that guides other components into proper position during assembly. This parameter change reduces the need for precise pre-machining of multiple components, allowing faster assembly while maintaining proper alignment
Solution Approach 2:
The frustoconical permanent magnet acts as a self-aligning element that automatically positions other magnetic circuit components correctly during assembly. This self-service alignment feature eliminates the need for complex alignment procedures or highly precise machining of multiple components, reducing assembly time
3Reliability
If complex shaped components are used, then the actuator can provide sufficient holding force, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent simplifies the overall component geometry by using a frustoconical permanent magnet instead of multiple complex machined parts. This single parameter change (the frustoconical shape) replaces the need for several complex-shaped components, reducing device complexity while maintaining holding force
Solution Approach 2:
The frustoconical permanent magnet serves multiple functions simultaneously: it generates the magnetic field, provides flux concentration, acts as a positioning feature, and serves as a structural element. This merging of functions into a single component reduces the total number of parts and overall device complexity
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 approach reduces manufacturing and assembly costs while maintaining performance by allowing for variations in component tolerances, ensuring efficient and consistent actuator operation with minimal impact on holding force and positioning accuracy.
Implementation Method 1
a permanent magnet that induces a magnetic flux flow through the magnetic circuit so as to generate a magnetic force
Implementation Method 2
generate a magnetic force and an armature selectively movable within an opening formed through the bobbin responsive to the magnetic force
Implementation Method 3
The field attracts the plunger or armature that, in turn, moves, thus providing the required actuation
Data Source
AI summary
An electromagnetic actuator includes a housing and a bobbin positioned within the housing and secured relative thereto so as to be centered therein, the bobbin comprising a bobbin formed of a non-magnetic material. The electromagnetic actuator also includes a coil wound about the bobbin and a magnetic circuit comprising a plurality of actuator components positioned within the housing and on or adjacent to the bobbin. The actuator components include a permanent magnet that induces a magnetic flux flow through the magnetic circuit so as to generate a magnetic force, and an armature selectively movable within an opening formed through the bobbin responsive to the magnetic force and to current selectively provided to the coil. The bobbin locates and centers the components of the magnetic circuit about the central axis and provides a bearing surface for the armature as it moves within the opening formed through the bobbin.