Electromagnetic Valve Spring Ring Design for Cost Reduction
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Solution Overview
Problem
The production of electromagnetic valves for slip-controlled motor vehicle brake systems is hindered by the high costs associated with precisely manufacturing burr-free and thin-walled spring washers, which are necessary for achieving desired spring characteristics.
Innovation Solution
The design replaces the spring washer with a spring ring that is arranged in parallel with a restoring spring between the magnet armature and magnet core, utilizing a bore with distinct sections to support the spring ring and maintaining a residual air gap, allowing for variable stroke control and increased stiffness without the need for a spring washer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a spring washer is used to achieve desired spring characteristics, then the electromagnetic valve can be produced with conventional manufacturing methods, but the production costs increase due to the need for precise manufacturing without burrs and with thin walls
Solution Approach 1:
The patent replaces the expensive spring washer with a spring ring that can be produced more economically. The spring ring design allows for standard manufacturing processes without requiring the high precision and burr-free surfaces needed for spring washers, thereby reducing production costs while maintaining the necessary spring characteristics.
Solution Approach 2:
The invention changes the geometric parameters and material properties of the spring element by transitioning from a spring washer to a spring ring configuration. This parameter change enables the use of more cost-effective manufacturing methods while achieving the desired spring characteristics and stroke control.
2Adaptability or versatility
If a spring washer is used for stroke control, then variable stroke control can be achieved, but the device complexity increases due to the need for precise production of thin-walled components
Solution Approach 1:
The spring ring replaces the complex spring washer, simplifying the production process while maintaining variable stroke control capability through the parallel arrangement with the restoring spring.
3Measurement precision
If the residual air gap is maintained precisely, then the electromagnetic valve operates efficiently, but the manufacturing precision requirements increase
Solution Approach 1:
The spring ring acts as an intermediary element between the magnet armature and magnet core, providing a mechanical means to maintain the residual air gap. This intermediary structure allows for precise air gap control through the spring's inherent mechanical properties rather than relying solely on precision manufacturing of all components.
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 reduces production costs, ensures precise maintenance of the residual air gap, and achieves higher spring stiffness at small air gaps, enabling efficient and cost-effective electromagnetic valve operation with reduced electrical power requirements.
Implementation Method 1
the magnet armature 2 connected to the valve closing element is, in a manner known per se, electromagnetically actuated in the direction of the magnet core 5 by means of a valve coil
Implementation Method 2
under the permanent action of a restoring spring 8 arranged between a magnet armature 2 and a magnet core 5, is capable of closing a valve passage in a valve seat
Data Source
AI summary
An electromagnetic valve, having a valve closing element which is arranged in a valve housing and which is capable of opening or closing a valve passage in a valve seat, having a magnet armature provided for actuating the valve closing element, and having a substantially cylindrical restoring spring which is braced between the magnet armature and a magnet core. In a parallel arrangement with respect to the restoring spring, a spring ring is arranged between the magnet armature and the magnet core, which spring ring has a smaller number of spring windings in relation to the number of spring windings of the restoring spring.