Electromagnetic Actuator Magnetic Path Assembly With Fewer Parts
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Solution Overview
Problem
Conventional electromagnetic actuators with cylindrical stators face challenges in securing a necessary magnetic path area due to gaps between crimped parts, increasing complexity and cost, and require additional positioning components, leading to a complex structure and higher costs.
Innovation Solution
The electromagnetic actuator design simplifies the structure by using a tube member with an annular end face of equal plate thickness, metallurgically joined to a flat plate member, and crimping pieces to secure the magnetic path, reducing the number of parts and costs while ensuring smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping method is used to fix the bracket to the housing, then the bracket can be fixed to the housing, but a gap occurs between the inner peripheral wall of the crimped part and the outer peripheral wall of the disk-shaped part, making it difficult to secure necessary magnetic path area
Solution Approach 1:
The housing end is divided into two separate components: the main housing body and an annular end face plate. This segmentation allows the magnetic path to be established through the end face plate rather than relying on a gap-free crimped connection, thereby securing the necessary magnetic path area while maintaining ease of assembly.
Solution Approach 2:
The annular end face plate acts as an intermediary component between the housing and the bracket. It provides a dedicated surface for magnetic flux passage, mediating the connection and ensuring adequate magnetic path area without requiring perfect contact between the crimped parts.
2Ease of operation
If a collar of cylindrical shape is adopted to position the yoke and the core, then the plunger and the pin can be smoothly moved, but the number of parts is increased, the structure becomes complex, and the cost is increased
Solution Approach 1:
The positioning function previously performed by a separate cylindrical collar is merged into the bobbin structure. The bobbin now incorporates both the coil winding support function and the positioning function, eliminating the need for a dedicated collar component while maintaining smooth movement of the plunger and pin.
Solution Approach 2:
The bobbin is designed to perform multiple functions: it serves as the support structure for the coil, provides electrical insulation, and simultaneously acts as a positioning element for the yoke and core. This multi-functionality reduces the total number of parts while maintaining the smooth operation required for mover movement.
3Ease of manufacture
If the housing is of a bottomed shape, then the housing can be formed by forging or cutting, but the cost is increased
Solution Approach 1:
The housing is segmented into a main body portion and a separate annular end face plate. This allows the main body to be formed by cost-effective methods such as sheet metal forming or stamping, while the end face plate can be separately manufactured and attached, reducing overall material costs compared to forming a complete bottomed housing through expensive forging or cutting processes.
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 secures the necessary magnetic path area, reduces the number of parts and costs, 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
Implementation Method 2
a tube member, surrounding the bobbin, connected to the first stator, forming a magnetic path
Data Source
AI summary
An electromagnetic actuator includes: a mover, reciprocating along an axis line; a first stator and a second stator, accommodating the mover to be capable of reciprocating and arranged spaced apart in the direction of the axis line; a bobbin, arranged around the first stator and the second stator and around which a coil for excitation is wound; a tube member, surrounding the bobbin, connected to the first stator, forming a magnetic path and having a predetermined plate thickness; and a flat plate member, connected to the second stator and the tube member and forming a magnetic path. The tube member includes an annular end face having a width equal to the plate thickness on one end in the direction of the axis line, and is fixed to the flat plate member by metallurgical joining or press fitting with the annular end face closely joined to the flat plate member.