Bi-stable Solenoid Switch Magnetic Coupling Member
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Solution Overview
Problem
Existing bi-stable solenoid switches face limitations in operating voltage range and experience high temperature rise due to high current usage, necessitating a solution for a wide operating voltage range with reduced power consumption.
Innovation Solution
A bi-stable solenoid switch design featuring a solenoid bobbin with coil windings, a magnetic coupling member, and a plunger with conductive plates, where the magnetic coupling member reduces the magnetic force required to maintain the solenoid in an open position, allowing operation across a wide voltage range (5 to 32 volts) with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bi-stable solenoid switches are used to achieve wide operating voltage range, then the operating voltage range is improved, but the temperature rise increases due to high current usage
Solution Approach 1:
The patent implements dynamic current control by transitioning from a static high-current design to a dynamic system that adjusts current based on operational state. The solenoid operates in two distinct modes: a high-current pulse mode for initial actuation and a low-current hold mode for maintaining position, thereby adapting the current level to the specific operational requirement and reducing overall temperature rise.
Solution Approach 2:
The patent changes the electrical parameters of the solenoid operation by introducing a dual-mode current regime. The system switches between different current magnitudes (high initial current versus low holding current) and different duty cycles, thereby modifying the effective power dissipation and thermal characteristics while preserving the wide voltage range capability.
2Force
If high current is used in bi-stable solenoid switches, then the magnetic field strength is improved, but the power consumption increases
Solution Approach 1:
The patent employs periodic action through pulsed current delivery, where a high-current pulse is applied only during the brief moment needed to overcome the latching force and change the solenoid state. Once the desired position is achieved, the current is reduced to a minimal holding level or completely switched off, since the bi-stable mechanism maintains the position without continuous power. This periodic excitation pattern provides sufficient magnetic field strength when needed while minimizing average power consumption.
Solution Approach 2:
The patent utilizes preliminary action by applying a high-current pulse in advance to achieve the state transition, after which the system enters a low-power maintenance mode. The initial energy input prepares the system for subsequent operation at reduced power levels, as the bi-stable latching mechanism preserves the achieved state without requiring continuous high current input.
3Force
If conventional solenoid design is used, then the magnetic field generation is improved, but the operating voltage range is limited
Solution Approach 1:
The patent achieves universality by designing the solenoid system to function effectively across multiple voltage levels (5V to 32V) through a unified dual-mode control architecture. The same solenoid structure and control mechanism handle both low-voltage and high-voltage operations, adapting the current pulse characteristics according to the applied voltage while maintaining consistent performance. This eliminates the need for voltage-specific designs and broadens the operational versatility.
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 design enables the solenoid switch to maintain a stable open position with reduced magnetic force, supporting a wide operating voltage range while minimizing power usage and preventing contact degradation.
Implementation Method 1
the coil windings, which when engaged by a power source, generate a magnetic field
Implementation Method 2
The magnetic field latching and unlatching the plunger between the at least two positions
Implementation Method 3
The magnetic coupling member configured to reduce the force needed by the magnetic field for allowing the solenoid to remain in an open position
Data Source
AI summary
An improved bi-stable electrical solenoid switch comprising a solenoid being wound with coil windings. The solenoid having a central aperture defined therein, and the coil windings, which when engaged by a power source, generates a magnetic field. A magnetic coupling member mounted on the solenoid. A plunger partially disposed in the central aperture for movement into and out of the central aperture. A conductive plate coupled to the plunger and provided with contacts on each end of the conductive plate. The conductive plate configured to electrically engage and disengage the solenoid upon respective application of power to the solenoid. The magnetic coupling member configured to reduce the force needed by the solenoid to remain in an open position when selectively energized for moving and retaining the conductive plate of the plunger against the solenoid for allowing wide operating voltage and reduced operating power.