Electromagnet Armature Impact Plunger Design
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Solution Overview
Problem
Electromagnets experience wear and changes in switching behavior due to high impact energy during repeated operations, leading to potential bursting of the armature and deterioration of running properties.
Innovation Solution
An impact plunger is movably mounted in the armature, with its end face protruding beyond the armature end face in the de-energized state, and an elastic element, such as a plunger spring, is used to absorb kinetic energy, reducing the impact on the pole core and improving the armature's fall behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the armature is allowed to collide directly with the pole core to achieve strong magnetic field response, then the switching speed is improved, but the armature experiences high impact energy causing wear and bursting
Solution Approach 1:
The patent introduces an impact plunger as an intermediary element between the armature and the pole core. The plunger absorbs the impact energy during armature collision, preventing direct damage to the armature while maintaining the magnetic field response function. The plunger acts as a mediator that converts harmful impact energy into useful compression of the elastic element.
Solution Approach 2:
The patent employs an elastic element (such as a spring) positioned behind the impact plunger to provide beforehand cushioning. This elastic element is pre-positioned to absorb impact energy when the armature collides with the pole core, preventing the high impact energy from damaging the armature structure before it can cause bursting.
2Speed
If the armature mass is reduced to improve switching behavior, then the response time is improved, but the structural strength is reduced
Solution Approach 1:
The patent segments the armature structure by separating the impact-absorbing function (handled by the impact plunger and elastic element) from the magnetic field response function (handled by the armature proper). This allows the armature to be optimized for lightness and fast response while the impact plunger handles the mechanical stress of collision.
Solution Approach 2:
The impact plunger serves as a mediator that protects the armature structure from impact damage. This allows the armature to be designed with reduced mass for faster response without compromising structural strength, as the plunger absorbs the collision forces.
3Force
If the air gap is reduced to improve magnetic field efficiency, then the magnetic field strength is improved, but the risk of armature bursting is increased
Solution Approach 1:
The elastic element provides beforehand cushioning by being pre-positioned to absorb impact energy. When the air gap is reduced for stronger magnetic field, the armature collision force increases, but the pre-positioned elastic element absorbs this increased energy, preventing armature bursting.
Solution Approach 2:
The impact plunger acts as an intermediary that decouples the relationship between air gap size and armature stress. This allows the air gap to be optimized for magnetic field strength independent of the armature's mechanical stress, as the plunger absorbs the collision forces.
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 enhances the reliability and switching behavior of the electromagnet by reducing wear and preventing armature bursting, allowing for a longer service life and improved mechanical properties with potential savings in coil material.
Implementation Method 1
If electric current is applied to the current winding, the magnetic field forms inside the coil, particularly in the armature space, and acts on the armature
Implementation Method 2
an elastic element, in particular a plunger spring for the impact plunger, is provided in the armature and the elastic element is compressed when the armature moves against the pole core
Data Source
AI summary
Solenoid (1) comprises one armature (2) supported in an armature space (14), which is encircled by a coil carrying a number of windings (12), which can be loaded with current, where magnetic field generated when loaded with current moves the armature against a pole core (10). In the armature, a rebounding tappet (4) is supported moving on bearings; and in unelectrified condition, the distance between the front of the tappet and the core is smaller than the distance between the front of the armature and the pole core. An independent claim is included for valve (7), particularly pneumatic valve.