Electromagnetic Actuator Stabilization Without Magnet
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Solution Overview
Problem
Existing electromagnetic actuators that provide three-position stability are complex and costly due to the presence of a magnet and additional coils required for better stability in the intermediate position.
Innovation Solution
An electromagnetic actuator design featuring ferromagnetic coils with armatures, a ferromagnetic plunger, and a guide member that uses projections and flanges to stabilize the plunger in three positions without the need for a magnet or additional coils, utilizing laser welding for assembly, and a guide rod to minimize friction and enhance magnetic flux guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a magnet and additional coil are used to stabilize the plunger in the intermediate position, then the stability of the intermediate position is improved, but the device complexity and cost increase
Solution Approach 1:
The patent removes the magnet and additional stabilization coil from the actuator design. Instead of using these separate components to stabilize the intermediate position, the invention relies solely on the magnetic fields generated by the two main coils to achieve three-position stabilization, thereby reducing device complexity while maintaining stability.
Solution Approach 2:
The two main electromagnetic coils serve dual functions: they generate magnetic fields to move the plunger to extreme positions and simultaneously provide stabilization at the intermediate position through their combined magnetic field interaction. This eliminates the need for dedicated stabilization components, reducing overall device complexity.
2Stability of the object's composition
If a magnet and additional coil are used to stabilize the plunger in the intermediate position, then the stability of the intermediate position is improved, but the volume of the actuator increases
Solution Approach 1:
By removing the magnet and additional stabilization coil, the patent reduces the overall volume of the actuator. The space previously occupied by these components is eliminated, resulting in a more compact design while maintaining three-position stabilization capability through the existing coil system.
3Ease of manufacture
If traditional manufacturing methods are used to assemble the actuator components, then the assembly process is simple, but the manufacturing precision and alignment of magnetic components deteriorate
Solution Approach 1:
The patent replaces traditional mechanical assembly methods with laser welding technology. This substitution enables precise alignment and permanent bonding of magnetic components (carcass, plunger, and ferromagnetic member) with high manufacturing precision, while the automated nature of laser welding maintains ease of manufacture through process efficiency.
Solution Approach 2:
The invention changes the manufacturing parameter from mechanical assembly to laser welding, which provides superior precision for aligning magnetic components. This parameter change ensures accurate positioning of the ferromagnetic member relative to the carcass and plunger, optimizing magnetic flux paths while maintaining manufacturing efficiency.
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 achieves improved mechanical stability in the intermediate position with reduced cost and volume, minimizing magnetic reluctance and leakage flux, while maintaining efficient operation by guiding magnetic flux effectively without additional components.
Implementation Method 1
a ferromagnetic plunger (22) subjected to a magnetic field generated by the coils (14, 16)
Implementation Method 2
two electromagnetic coils (14, 16) arranged inside the casing (12), each comprising at least one winding around the longitudinal direction (X)
Implementation Method 3
a member (24) for guiding a magnetic flux generated by the coils (14, 16) from a first position to a second position
Implementation Method 4
minimizing magnetic reluctance and leakage flux
Implementation Method 5
during step c), the ferromagnetic member is fixed by laser welding to the carcass
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to an electromagnetic actuator (10), which includes a ferromagnetic housing (12) extending in a longitudinal direction (X) and having a height (H1) in a vertical direction (Z) perpendicular to the longitudinal direction (X), two coils (14, 16) arranged inside the housing and each comprising at least one winding (36, 38) around the longitudinal direction (X), a ferromagnetic member (24) arranged between the coils, and a ferromagnetic plunger (22) subjected to a magnetic field generated by the coils, the plunger being movable in the longitudinal direction and suitable for being immobilized in three different longitudinal positions depending on the field generated by the coils. The ferromagnetic member (24) is rigidly connected to the housing (12) and has, in the vertical direction (Z), a size (H2) that is greater than one sixth of the height (H1) of the housing, the ferromagnetic member (24) being in addition located at a distance that is smaller than one fourth of a gap (E) in the longitudinal direction (X) between the two coils, relative to a median plane (P) that is perpendicular to the longitudinal direction and located at the midpoint between the two coils.