Electromagnet Actuating Unit With Integrated Armature Position Sensing
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Solution Overview
Problem
Existing drive units lack a efficient and integrated solution for switching the coupling between a shaft and a rotational drive element, which is necessary for applications such as decoupling vehicle drives to prevent engine braking or implementing all-wheel-drive systems.
Innovation Solution
An actuating unit for an electromagnet that includes a magnetic coil, a housing attached to the radial outside of the magnetic coil, and a magnetic field sensor integrated in the housing, which enables the detection of the armature position and controls the magnetic field to switch the coupling state between the shaft and the rotational drive element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic field sensor is separately fastened to the drive unit, then the armature position can be detected, but additional wiring expenditure and complex components are required
Solution Approach 1:
The magnetic field sensor is integrated directly into the housing of the actuating unit, merging the sensing function with the structural component. This eliminates the need for separate fastening and additional wiring, reducing device complexity while maintaining position detection capability. The housing itself becomes the mounting structure for the sensor.
Solution Approach 2:
The housing serves dual functions: providing structural support and housing the magnetic field sensor. This multi-functionality reduces the need for separate components and simplifies the overall device architecture, addressing the contradiction between measurement capability and device complexity.
2Device complexity
If an actuating unit with integrated magnetic field sensor is used, then circuitry expenditure is reduced, but the housing must be designed to accommodate the sensor
Solution Approach 1:
The housing is designed to integrate the magnetic field sensor, combining structural and sensing functions. This reduces circuitry expenditure and overall device complexity, while the housing design incorporates sensor mounting features that simplify rather than complicate manufacturing.
3Productivity
If the magnetic coil is annular and the armature is actuated axially, then the coupling state can be switched efficiently, but the magnetic field generation and armature movement must be precisely coordinated
Solution Approach 1:
The mechanical coupling switching is replaced by electromagnetic actuation through the annular magnetic coil. The coil generates a magnetic field that directly actuates the armature axially, eliminating the need for complex mechanical linkage and improving switching efficiency. The coordination is achieved through the inherent electromagnetic coupling between the coil and armature.
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 proposed solution achieves a high level of integration, reduces circuitry expenditure, and allows for efficient switching of the coupling state, thereby enabling applications such as decoupling vehicle drives and implementing all-wheel-drive systems without the need for additional wiring or complex components.
Implementation Method 1
a magnetic coil, wherein the magnetic coil is annular
Implementation Method 2
a magnetic field sensor fastened to or integrated in the housing
Data Source
AI summary
An actuating unit for an electromagnet for actuating an annular armature, wherein the actuating unit comprises a magnetic coil, a housing, and a magnetic field sensor integrated in the housing. Also disclosed is an electromagnet having such an actuating unit as well as a drive unit having such an electromagnet.