Electromagnetic Valve Core Winding Configuration
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Solution Overview
Problem
The demand for smaller valves has led to reduced construction volume and performance, limiting the maximum mechanical performance of magnetic coils due to space constraints, which hinders achieving high throughput and magnetic force with the same dimensions.
Innovation Solution
The design incorporates a configuration where the pole pieces are integral with the core, and the armature is positioned outside the winding, eliminating the air gap and allowing more space for coil windings, thereby increasing magnetic force while maintaining the same dimensions, and using laminated laminations to reduce eddy current losses and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the valve dimensions are reduced to meet market demand for smaller valves, then the installation volume is reduced, but the magnetic force and throughput are reduced
Solution Approach 1:
The patent positions the armature outside the winding in a different spatial dimension, eliminating the air gap that would otherwise be required. This dimensional reconfiguration allows the magnetic circuit to be more efficient without increasing the overall valve dimensions, thereby maintaining small size while improving magnetic force.
Solution Approach 2:
The core and pole pieces are merged into a single integral component, eliminating air gaps at the interfaces between separate parts. This merging improves magnetic flux density and strengthens the magnetic force while keeping the valve compact.
2Force
If more coil turns are accommodated to increase magnetic flux density, then the magnetic force is improved, but the installation volume increases
Solution Approach 1:
By positioning the armature outside the winding, the patent creates additional space within the winding area that can be used for more coil turns. This spatial reconfiguration allows increased magnetic flux density without proportionally increasing the overall valve volume.
Solution Approach 2:
The air gap between the winding and armature is eliminated by extracting the unnecessary space, allowing the winding to be positioned more efficiently and accommodate more turns within the same volume envelope.
3Volume of moving object
If the armature is positioned inside the winding, then the overall dimensions are reduced, but an air gap is created that reduces magnetic force
Solution Approach 1:
Instead of positioning the armature inside the winding as in conventional designs, the patent inverts this arrangement by positioning the armature outside the winding. This inversion eliminates the air gap while maintaining compact dimensions through efficient spatial utilization.
Solution Approach 2:
The armature is repositioned in a different spatial dimension relative to the winding, moving from an internal position to an external position that eliminates the air gap while maintaining overall compactness through optimized spatial arrangement.
4Ease of manufacture
If conventional iron is used instead of ferrite for cost reasons, then manufacturing cost is reduced, but eddy current losses increase
Solution Approach 1:
The core and pole pieces are segmented into laminated sheets rather than being made as solid pieces. This segmentation into thin layers reduces eddy current paths, thereby reducing energy losses while using cost-effective conventional iron material instead of expensive ferrite.
Solution Approach 2:
The patent uses laminated sheet metal construction, creating a composite structure of multiple thin layers. This composite approach reduces eddy current losses compared to solid conventional iron, achieving a balance between cost and energy efficiency.
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 configuration enables a compact valve with high performance, allowing for greater throughput and reduced structural dimensions, making it suitable for space-saving applications like microtiter plates and 384-well plates, while maintaining performance comparable to prior art.
Implementation Method 1
The actuator (10) has a core (12), which is arranged between two pole pieces (14)... A winding (16), consisting of a plurality of copper turns, is applied to the core (12)... The winding (16) rests on the core (12) without an interposed coil former wall
Implementation Method 2
the core and pole pieces then being made from layered sheets (i.e., 'laminated') to avoid eddy current losses
Data Source
Figure 1~6
Figure 7~8
Figure 9~10
AI summary
A valve having an electromagnetic drive (10) including a core (12) that is arranged between two pole pieces (14) and has a winding (16) applied thereon which, at least in the direction of a dimension (B) determining the structural size of the valve (1), rests on the core (12) without a bobbin wall interposed.