Perpendicular Dual-Coil Solenoid Valve for Low-Profile Packaging
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Solution Overview
Problem
Dual coil solenoid valves used in industrial and agricultural machinery are typically large and cumbersome, leading to space claim issues and susceptibility to damage during shipment and use due to their tall profile.
Innovation Solution
A compact dual coiled solenoid valve design with a perpendicular actuation architecture, providing 360-degree variability, a serviceable spool, changeable valve logic, and a visual position indicator, along with a standard industrial cavity mating system, which reduces space requirements and allows for easier maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If dual coil solenoid valves are designed with traditional architecture, then they provide reliable actuation functionality, but they become large and cumbersome with tall profile leading to space claim issues
Solution Approach 1:
The patent reorients the armature axis perpendicular to the spool axis, changing the traditional linear alignment. This dimensional change allows the solenoid actuator to project laterally rather than extending axially, reducing the overall length and height of the valve while maintaining the actuation function. The armature rotates about an axis perpendicular to the spool axis, enabling compact packaging of components.
Solution Approach 2:
The armature is positioned within the solenoid housing, and the spool actuator extends from the armature to engage the spool. This nested arrangement places components within each other's spatial envelopes, with the armature housed within the solenoid assembly and the spool actuator integrated between them, maximizing space utilization and reducing overall valve dimensions.
2Force
If dual coil solenoid valves are designed with traditional architecture, then they provide sufficient actuation force, but they become susceptible to damage during shipment and use due to tall profile
Solution Approach 1:
By changing the armature axis to be perpendicular to the spool axis, the actuation force is applied through a lateral projection rather than axial extension. This reduces the tall profile that makes traditional valves susceptible to damage during handling and shipment, while the dual coil configuration maintains sufficient actuation force through electromagnetic forces applied perpendicular to the spool axis.
3Volume of moving object
If compact design is implemented, then space requirements are reduced, but device complexity increases due to perpendicular actuation architecture
Solution Approach 1:
The perpendicular arrangement of armature axis to spool axis creates a compact footprint by utilizing lateral space rather than axial space. The armature rotates about a perpendicular axis and the spool actuator projects laterally to engage the spool, achieving compact dimensions while the modular design keeps the complexity manageable through clear functional separation.
Solution Approach 2:
The perpendicular actuation architecture provides 360-degree variability of solenoid position about the valve spool axis, enabling the same basic design to serve multiple valve configurations and applications. This multi-functionality justifies the increased complexity by providing greater design flexibility and adaptability.
4Ease of manufacture
If traditional solenoid valve design is used, then manufacturing is straightforward, but maintenance and repair become difficult due to integrated structure
Solution Approach 1:
The valve is divided into distinct functional modules: the solenoid housing containing the armature and coils, the spool housing containing the spool and spool actuator, and the interface between them. This segmentation allows the spool and spool actuator to be serviced independently from the solenoid assembly, improving maintenance accessibility while keeping manufacturing processes for each module relatively simple.
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 compact design addresses space and durability issues, enabling more efficient use in machinery while maintaining functionality and allowing for easy replacement and adjustment of valve components.
Implementation Method 1
one or more coils positioned along the armature. The one or more coils are controllable to reposition the armature along the armature axis
Data Source
AI summary
A solenoid valve includes a spool housing defining a spool axis, a spool extending within the spool housing, a solenoid housing, an armature extending within the solenoid housing and defining an armature axis perpendicular to the spool axis, a spool actuator extending from the armature and in engagement with the spool, a first coil positioned along a first portion of the armature, and a second positioned along a second portion of the armature. The first coil and the second coil are controllable to reposition the armature along the armature axis such that the spool actuator variably engages with the spool to move the spool between a plurality of positions along the spool axis.