Electromagnetic Actuator Layout for Compact Coil Heat Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electromagnetic actuators for piston compressors face challenges in achieving compact design, low maintenance, high reliability, and long service life, particularly in large compressors where high power coils generate excessive heat, necessitating complex and space-consuming arrangements for power electronics to avoid overheating.
Innovation Solution
The power electronics are integrated within the actuator housing between the coil and the axial actuator end, with a thermally conductive housing wall and heat conducting elements to facilitate heat dissipation, allowing for improved thermal management and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If powerful coils are used to move large masses in large compressors, then the actuation force is sufficient, but the installation space increases and heat generation becomes excessive
Solution Approach 1:
The patent combines the power electronics and coil assembly into a single integrated actuator housing, eliminating the need for separate external housing and reducing overall installation space. The power electronics are positioned adjacent to the coil within the same housing, merging previously separate components into a compact unified structure.
Solution Approach 2:
The power electronics are nested within the actuator housing in close proximity to the coil, with the housing wall positioned between them. This nested arrangement allows the power electronics to be contained within the same spatial envelope as the coil assembly, significantly reducing the total volume required for the actuator system.
2Force
If powerful coils are used to move large masses in large compressors, then the actuation force is sufficient, but the heat generated increases excessively
Solution Approach 1:
The housing wall serves as a thermal intermediary between the coil and the power electronics. It is positioned between these two heat-generating components to facilitate heat dissipation, acting as a heat sink that conducts away thermal energy and prevents excessive temperature buildup in both the coil and power electronics.
Solution Approach 2:
The housing wall is strategically positioned to extract heat from the coil and power electronics by serving as a thermal pathway to the external environment. This extraction of thermal energy prevents temperature buildup and allows the actuator to operate at high power levels without overheating.
3Reliability
If power electronics are arranged in a separate housing to protect them from high temperatures, then the reliability of electronic components is improved, but the device complexity and installation space increase
Solution Approach 1:
The patent merges the power electronics housing with the actuator housing into a single integrated structure. The power electronics are positioned within the actuator housing adjacent to the coil, with the housing wall providing thermal separation. This integration eliminates the need for separate external housing and connecting lines, reducing system complexity while maintaining component protection.
4Volume of stationary object
If power electronics are arranged closer to the coil, then the installation space is reduced, but the risk of overheating for electronic components increases
Solution Approach 1:
The housing wall is positioned between the coil and power electronics to serve as a thermal intermediary. This wall provides thermal separation and acts as a heat sink, conducting heat away from the power electronics while allowing them to be positioned close to the coil for compact integration.
Solution Approach 2:
The housing wall provides localized thermal management by being positioned specifically between the heat-generating coil and the temperature-sensitive power electronics. This local thermal barrier creates a favorable thermal environment for the power electronics in the high-temperature region near the coil.
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 enables efficient heat dissipation, reduces the risk of overheating for sensitive electronic components, and maintains reliable operation while minimizing space requirements, thus addressing the limitations of previous actuators.
Implementation Method 1
The heat can thereby advantageously be dissipated from the interior of the actuator via the housing wall to the actuator housing and via the axial actuator end, for example, to a compressor housing of a piston compressor
Implementation Method 2
the power electronics are separated from the coil by a housing wall of the actuator housing
Data Source
AI summary
Aspects of the present disclosure are directed to an electromagnetic actuator for actuating a valve of a piston compressor. Power electronics of the actuator are arranged in an actuator housing between a coil and an axial actuator end of the actuator, on which an actuation opening for an actuation element is provided, wherein the power electronics are separated from the coil by a housing wall of the actuator housing, wherein a printed circuit board of the power electronics is arranged on a fastening surface provided on the housing wall, wherein electrical coil contacts of the coil extend through the housing wall and are connected to the printed circuit board.