Deep-drawn Non-magnetic Housing for Electromagnetic Actuator Sealing
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Solution Overview
Problem
Existing electromagnetic positioning devices face high production costs and complexity, especially when dealing with reactive gases like hydrogen, due to the difficulty in machining silicon-alloyed metal materials and ensuring reliable sealing without compromising magnetic flux or mechanical integrity.
Innovation Solution
A pot-like or cup-like housing made of non-magnetic, deep-drawable metal (such as stainless steel) surrounds the coil and winding, providing a simple and effective sealing solution while maintaining magnetic efficiency, and the use of stacked sheet metal or sinter material cores reduces production complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a pot-like core assembly made of silicon-alloyed metal is used to protect coil means from reactive gases, then protection against harmful gases is improved, but manufacturing complexity and cost increase due to difficulty in machining and assembly
Solution Approach 1:
The invention changes the material parameter from silicon-alloyed metal to non-magnetic metal (such as aluminum or stainless steel) that is suitable for deep-drawing processes. This material substitution enables transition from complex machining operations to simpler forming processes, reducing manufacturing complexity while maintaining protective functionality against reactive gases.
Solution Approach 2:
The invention replaces the mechanical machining process with a deep-drawing forming process. Instead of cutting and shaping hard silicon-alloyed metal through complex machining operations, the non-magnetic metal housing is formed through plastic deformation in a single piece, significantly simplifying the manufacturing process and reducing assembly steps.
2Reliability
If a single-piece pot-like core assembly is used for sealing, then sealing reliability is improved, but manufacturing cost increases due to complex production processes
Solution Approach 1:
The invention replaces complex machining operations with deep-drawing forming processes. The single-piece housing is formed through plastic deformation rather than subtractive machining, which is both cheaper and more suitable for mass production while maintaining the sealing integrity provided by the monolithic structure.
Solution Approach 2:
The invention changes the material parameters to include non-magnetic metals with good deep-drawability (such as aluminum alloys or austenitic stainless steels). These materials can be formed into complex shapes through deep-drawing at lower cost compared to machining silicon-alloyed metals, while maintaining the required sealing properties.
3Loss of energy
If low wall thickness is used in the base section to avoid magnetic saturation, then magnetic circuit efficiency is improved, but structural strength and sealing capability deteriorate
Solution Approach 1:
The invention changes the material parameter from magnetic (silicon-alloyed) metal to non-magnetic metal. This eliminates the magnetic saturation issue entirely, allowing the base section to be designed with optimal thickness for both magnetic flux conduction (through the core) and structural strength (in the housing), without the trade-off that exists in magnetic materials.
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
This design enhances protection against reactive gases, simplifies production, and allows for cost-effective large-scale manufacturing while maintaining magnetic circuit efficiency and mechanical integrity, making it suitable for applications like hydrogen fuel cell technology.
Implementation Method 1
core means, which conduct magnetic flux
Implementation Method 2
armature means... are moved relative to stationary core means, which conduct magnetic flux, as a reaction to an energization of stationary coil means
Data Source
AI summary
An electromagnetic positioning device includes an armature member for actuating a positioning partner and movable in an armature space relative to a stationary core (30). The armature member conducts magnetic flux upon energization of a stationary coil (32). The coil has a coil support with a winding and at least one external contactable connector (46) embedded at least in sections in the core and/or surrounded by the core. The core has an end surface (34), which is planar at least in sections, for interacting with the armature member. The core and the coil are embedded in and/or surrounded by a one-piece pot-like and/or cup-like housing (38) made of a material suitable for deep-drawing in such a manner that the core rests on a membrane-like, continuous and closed base section of the housing, the base section realizing a boundary surface of the armature space.