Electromagnetic Actuator Assembly With Shared Coil Core and Damping

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Solution Overview

Problem

Existing electromagnetic actuators in vehicle braking systems face challenges in achieving high efficiency while maintaining low manufacturing costs, with damping elements often increasing magnetic resistance and noise, and different functional requirements leading to varied actuator types.

Innovation Solution

An electromagnetic actuator arrangement with identical coil designs for different actuator types, using structurally identical surfaces and damping devices where necessary, to combine high efficiency with low costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If damping elements are added to electromagnetic actuators to reduce noise, then noise is reduced, but magnetic resistance increases and efficiency decreases

Engineering Contradiction:

ImprovenoiseVSAvoidmagnetic resistance

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent applies different surface characteristics to different regions of the coil core. The first region has a first surface characteristic (smooth, no damping) for optimal magnetic coupling, while the second region has a second surface characteristic (with damping material) for noise reduction. This local differentiation allows the system to achieve both low magnetic resistance and noise reduction simultaneously.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If different types of electromagnetic actuators are used to meet different functional requirements, then functional requirements are satisfied, but manufacturing costs increase

Engineering Contradiction:

Improvefunctional requirementsVSAvoidmanufacturing costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent creates a universal coil core design that can serve multiple functions by incorporating different surface characteristics in different regions. The same coil core structure can be used for actuators requiring damping (noise reduction) and actuators requiring direct contact (high efficiency), eliminating the need for completely different actuator designs for different applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The coil core surface is segmented into different regions with different characteristics. The first region is designed for direct armature contact with smooth surface, while the second region has damping material applied. This segmentation allows a single coil core design to accommodate different functional requirements through selective region utilization.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If damping elements are added to electromagnetic actuators, then noise is reduced, but device complexity increases

Engineering Contradiction:

ImprovenoiseVSAvoidactuator structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the damping function directly into the coil core structure by applying damping material to specific regions of the coil core surface. This integration eliminates the need for separate damping components and simplifies the overall actuator structure, as the damping function is combined with the magnetic circuit component.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution enables high efficiency and reduced manufacturing costs by using a common coil design for actuators with or without damping elements, addressing noise and magnetic resistance issues.

Implementation Method 1

movable by a magnetic field generated by the first coil arrangement

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

magnetic field generated by the first coil arrangement

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

has a damping device attached to the second armature body

Methodology Applied

Scientific EffectDamping: Damping

Data Source

PatentEP4448355B1Electromagnetic actuator assembly, pressure control module, and vehicle braking system having an electromagnetic actuator assembly

Publication Date: 2025.10.15 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

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AI summary

An electromagnetic actuator assembly (101) comprises at least one first electromagnetic actuator (BV) having a first coil arrangement (201) with at least one first coil core (202) and a first coil (203, 204) and having a movable magnetic first armature body (208) which can be moved by a magnetic field generated by the first coil arrangement (201) from a first position into a second position (149) in which the first armature body (208) is attracted towards a first surface (205), which is different from the first coil core (202) and arranged opposite the first armature body (208), and contacts the first coil core (202), and at least one second electromagnetic actuator (EV, AV) having a second coil arrangement (301) with at least one second coil core (302) and a second coil (303, 304) and having a movable magnetic second armature body (308) which has a damping device (309) mounted on the second armature body (308) and which can be moved by a magnetic field generated by the second coil arrangement (301) from a first position into a second position (149) in which the second armature body (308) is attracted towards a second surface (305) and abuts against the second surface (305) by means of the damping device (309). The first surface (205) and the second surface (305) are identical in construction.