Electromagnetic Actuator Bobbin Structure for Stator Alignment
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Solution Overview
Problem
Conventional electromagnetic actuators with cylindrical stators have a complex structure and high cost due to the use of dedicated positioning collars, increasing the number of parts and assembly complexity.
Innovation Solution
The electromagnetic actuator simplifies its structure by using a bobbin with through holes and positioning ridges to align the stators, reducing the number of parts and assembly complexity, and incorporates a buffer unit for smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a dedicated positioning collar is used to align the first core part and second core part, then the mover can move smoothly, but the number of parts is increased and the structure becomes complex
Solution Approach 1:
The positioning function is merged into the bobbin structure by forming positioning protrusions directly on the bobbin body. The bobbin now serves dual purposes: supporting the coil and positioning the first core part and second core part. This eliminates the need for a separate positioning collar, reducing the number of parts while maintaining the smooth movement of the mover through proper alignment of the core parts.
2Manufacturing precision
If a dedicated positioning collar is used to align the first core part and second core part, then the axial centers are positioned accurately, but the cost is increased
Solution Approach 1:
The positioning function is integrated into the bobbin structure through positioning protrusions formed directly on the bobbin body. This eliminates the need for a separate positioning collar component, reducing part count and assembly steps. The alignment precision is maintained through the geometric design of the positioning protrusions that fit into corresponding recesses on the core parts, ensuring accurate axial center alignment without additional manufacturing cost.
Solution Approach 2:
The positioning function is extracted from a separate collar component and transferred to the bobbin structure itself. The positioning protrusions are formed directly on the bobbin body, converting a multi-component solution into a single-integrated solution. This reduces the number of parts that need to be manufactured and assembled, thereby lowering manufacturing cost while maintaining positioning accuracy.
3Manufacturing precision
If a dedicated positioning collar is used, then the first core part and second core part are positioned correctly, but the number of parts is increased
Solution Approach 1:
The positioning function is merged into the bobbin structure by forming positioning protrusions directly on the bobbin body. The bobbin now performs multiple functions: supporting the coil, maintaining structural integrity, and positioning the first core part and second core part. This integration eliminates the need for a separate positioning collar, reducing the total number of parts while ensuring correct positioning of the stators through the geometric design of the positioning protrusions.
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 configuration reduces costs, simplifies assembly, and ensures smooth operation of the mover, making it suitable for applications like cam switching mechanisms in internal combustion engines.
Implementation Method 1
an electromagnetic actuator using electromagnetic force of a solenoid as a driving force
Data Source
AI summary
An electromagnetic actuator includes: a mover, reciprocating along a predetermined axis line; a first stator and a second stator, accommodating the mover to be capable of reciprocating in a direction of the axis line and arranged spaced apart in the direction of the axis line; and a bobbin, arranged around the first stator and the second stator and around which a coil for excitation is wound. The bobbin includes: a through hole, through which the first stator and the second stator pass; and a positioning part, partially formed in the through hole, allowing the first stator and the second stator to be fitted thereinto, and positioning the first stator and the second stator on the axis line.