Coil Capture Weld Ring for Pilot Operated Water Valve
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Solution Overview
Problem
Pilot operated water valves face challenges with high material costs due to increased copper prices and the need for a solenoid coil design that reduces copper usage while maintaining reliable operation and long life, along with securing the solenoid coil assembly to the valve body in a compact design.
Innovation Solution
A solenoid coil capture mechanism using a coil capture weld ring attached to the valve body, which can be spin welded or ultrasonically welded, with locking tabs to secure the solenoid coil assembly, allowing for flexible orientation and positive retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional solenoid coil assembly is used, then reliable actuation is achieved, but material costs increase due to high copper usage
Solution Approach 1:
The solenoid coil assembly is divided into separate components: the coil portion and the capture mechanism with locking tabs. This segmentation allows the coil to be optimized for minimal copper usage while the capture mechanism provides secure attachment, resolving the contradiction between material reduction and reliable actuation.
Solution Approach 2:
The coil capture weld ring with locking tabs is pre-installed on the valve body before the solenoid coil assembly is attached. This preliminary action ensures proper positioning and secure retention, maintaining reliable actuation while allowing for an optimized, copper-minimal coil design.
2Volume of moving object
If the solenoid coil assembly is made compact, then device size is reduced, but secure attachment becomes difficult
Solution Approach 1:
The locking tabs are integrated into the coil capture weld ring structure, with tabs extending from the ring body. This nested design allows the compact coil assembly to be securely attached to the valve body through the interlocking tabs and recesses, maintaining both compact size and secure attachment.
Solution Approach 2:
The locking tabs are positioned asymmetrically on the coil capture weld ring to engage with corresponding asymmetric features on the valve body. This asymmetric configuration ensures positive retention and secure attachment while maintaining a compact overall device size.
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 solenoid coil capture mechanism reduces material costs by minimizing copper usage and ensures reliable actuation and long operational life, while providing a secure attachment method for the solenoid coil assembly in a compact pilot operated water valve design.
Implementation Method 1
A solenoid coil capture mechanism using a coil capture weld ring attached to the valve body, which can be spin welded or ultrasonically welded
Implementation Method 2
A solenoid coil capture mechanism using a coil capture weld ring attached to the valve body, which can be spin welded or ultrasonically welded
Implementation Method 3
Many electronically controlled switching valves include an electrically actuated solenoid to directly act on a plunger connected to the valving member
Data Source
AI summary
Attachment mechanisms for capturing solenoid coil assemblies onto valves and valves incorporating same are described. Such mechanisms include weld rings attached to the valve body that have locking tabs to engage and hold the solenoid coil assembly. Two or more locking tabs are used. Inclusion of locking tab receiving locations on the solenoid coil frame or configuration of the end surface of the solenoid frame itself accommodate the locking tabs. The weld ring may be attached in an infinite number of orientations on the valve body. Attachment may be by spin welding or ultrasonic welding of the weld ring to the valve body in two embodiments.