Adjustable Solenoid Pole for Precision Air Gap Control
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Solution Overview
Problem
Conventional solenoid actuators require adjustments to spring pressure, current, or pulse-width modulation to set the air gap, which can lead to inefficiencies and loss in flux density due to the introduction of additional air gaps, making precise tuning and field adjustments cumbersome and inefficient.
Innovation Solution
An adjustable solenoid assembly with a threaded pole and interference fit sections allows for precise adjustment of the air gap between the pole and plunger without altering spring pressure or coil current, maintaining flux density by using complementary threaded and interference portions to control the solenoid's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical spacer is used to set the air gap, then the air gap can be controlled, but additional air gaps are introduced causing loss in flux density
Solution Approach 1:
The patent removes the mechanical spacer component entirely and replaces it with a threaded adjustment mechanism integrated into the pole structure. This eliminates the additional air gaps that would be introduced by a spacer, thereby preventing flux density loss while still achieving precise air gap control through direct threading into the solenoid body.
Solution Approach 2:
The patent introduces a threaded pole structure as an intermediary mechanism between the solenoid body and the plunger. This threaded structure allows for precise adjustment of the air gap without requiring separate spacing components, thereby maintaining magnetic flux density while enabling controlled adjustment.
2Manufacturing precision
If spring pressure or coil current is adjusted to tune the solenoid, then the air gap can be set, but the system becomes more complex and less efficient
Solution Approach 1:
The patent replaces complex electronic tuning mechanisms (spring pressure adjustment or coil current modulation) with a simple mechanical threaded adjustment system. The threaded pole can be directly adjusted to set the air gap, eliminating the need for additional springs, current regulation circuits, or PWM control systems, thereby reducing overall device complexity.
3Ease of operation
If field adjustments are made without special tools, then ease of operation improves, but precision may be compromised
Solution Approach 1:
The patent creates a dynamically adjustable pole structure with integrated threading that allows for both rough field adjustments using simple tools and fine precision adjustments. The threaded mechanism enables continuous adjustment along the thread pitch, allowing technicians to achieve precise air gap settings in the field without specialized equipment while maintaining manufacturing precision.
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
Enables precise tuning and adjustment of the solenoid without introducing additional air gaps, maintaining flux density and allowing for consistent output production, facilitating field adjustments without special tools and minimizing axial force, thus preventing valve misalignment and ensuring efficient operation.
Implementation Method 1
a coil for producing a magnetic field in an area of the assembly in response to electrical energization of the coil
Implementation Method 2
the interference portion of the adjustable pole is complementary to and interferingly engageable with the interference portion of the receiver
Data Source
AI summary
An adjustable solenoid assembly with an adjustable threaded pole having an interference fit section to be used with a complementary threaded receiver (e.g., the bore of the top plate) with an interference fit section. The adjustable threaded sections are used to pull or push the interference fit sections together and allow for precise locating of the interference fit sections and adjustment. The threaded pole may be used to set and maintain a precision working air gap between the pole piece and the plunger of the electromagnetic solenoid assembly. The interference fit holds the pole piece into location while still allowing the solenoid to be adjustable without a loss in flux density.