DC Electric Actuator Frustoconical Core Structure for Simpler Manufacturing
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Solution Overview
Problem
Existing direct current electric actuators for devices like washing machines and dishwashers require multiple complex processes to form the frustoconical structure, including cutting and bending, which complicates manufacturing and increases costs.
Innovation Solution
A direct current electric actuator with a blind frustoconical formation having a planar distal bottom wall, simplifying the manufacturing process by eliminating the need for cutting operations and enhancing core centring and force intensity through a complementary frustoconical configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the frustoconical formation is made with a terminal opening as in prior art, then the core is accessible from outside, but multiple complex manufacturing processes including cutting and bending are required
Solution Approach 1:
Instead of creating an open frustoconical formation requiring cutting operations, the patent inverts the approach by creating a blind frustoconical formation with a closed distal end. This is achieved by forming the frustoconical shape during the bending process without making any cutting operations, thereby simplifying manufacturing while achieving the same functional result through a different structural approach
Solution Approach 2:
The patent applies preliminary action by pre-forming the frustoconical shape during the initial bending process of the ferromagnetic strip. The frustoconical formation is created as an integral part of the body before final assembly, eliminating the need for subsequent cutting operations to create the terminal opening. This preliminary forming action reduces the total number of manufacturing steps
2Ease of manufacture
If multiple cutting and bending operations are used to form the frustoconical structure, then the terminal opening is created, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the frustoconical formation process with the initial bending operation of the ferromagnetic strip. Instead of performing separate cutting and forming operations, the frustoconical shape is integrated into the single bending process that forms the body. This combining of operations reduces both manufacturing cost and the risk of precision errors from multiple steps
Solution Approach 2:
The patent extracts the cutting operation from the manufacturing process entirely. By taking out the unnecessary cutting step and replacing it with a pure bending formation process, the patent eliminates the associated costs and complexity while maintaining the structural integrity and precision of the frustoconical formation through the bending process alone
3Force
If the frustoconical formation has a terminal opening, then the structure is open, but the force intensity on the core from rest position is reduced
Solution Approach 1:
The patent applies parameter changes by modifying the geometric parameters of the frustoconical formation. Specifically, it changes the opening parameter to a closed parameter (blind formation with distal end), which fundamentally alters the magnetic flux path and increases the magnetic field intensity. This parameter change from open to closed structure directly increases the force intensity on the core while maintaining the frustoconical shape's functional benefits
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 allows for a more economical and simplified manufacturing process while significantly increasing the force exerted on the movable core, with improved core centring and force intensity compared to prior art devices.
Implementation Method 1
a coil of insulated electrically conducting wire, fixed in said body such that the axis thereof extends in a direction essentially orthogonal to the lateral branches of said body, and a ferromagnetic core mounted so as to be movable with respect to said body in an axially translatable manner inside the coil, from a rest position to a working position, as an effect of the energising of the coil
Implementation Method 2
the frustoconical formation of the first branch of the aforesaid body defines an internal cavity having an essentially isosceles trapezium shaped profile in axial cross section... the solution according to the present invention can considerably increase the intensity of the force exerted on the movable core
Data Source
AI summary
The actuator (10) comprises a body (12) formed by a single strip of ferromagnetic material, U-shaped and including a first and a second lateral branch (14, 16) facing each other and interconnected by an intermediate branch or portion (18). A first lateral branch (14) of the body (12) has a frustoconical formation (30) which extends in the region outside the body (12). A coil (22) is fixed in the body (12), and its axis (A-A) extends in a direction essentially orthogonal to the lateral branches (14, 16) of this body (12). A ferromagnetic core (28) is mounted so as to be translatable inside the coil (22), from a rest position to a working position, as an effect of the energizing of the coil (22). One end (32) of the core (28), facing towards the first branch (14) of said body (12), has a frustoconical shape essentially complementary to the internal shape (30b) of the formation (30). The frustoconical formation (30) of the first branch (14) of said body (12) is blind and has a planar distal bottom wall (30a).