Electromagnetic Hammer Actuator for High-Force Motion
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Solution Overview
Problem
Traditional linear and rotary actuators are limited by extreme environments such as heat or cold, which weaken seals, jam gearboxes, or thicken lubricants, and they often require tight seals, gears, or lubrication, restricting their high force output capabilities.
Innovation Solution
A compact, high-force actuation system utilizing an inertial hammering motion from a voice-coil or pneumatic prime mover to transfer kinetic energy through an impact or impulse, exceeding the displacement and force capabilities of typical actuators by using a friction interface to generate significant motion and force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional linear or rotary actuators are used in extreme environments, then they can provide actuation, but seals weaken, gearboxes jam, and lubrication thickens reducing reliability
Solution Approach 1:
The invention removes seals, gearboxes, and lubrication systems from the actuator design, eliminating the components that fail in extreme environments. The electromagnetic hammer mechanism operates without these vulnerable parts, directly converting electromagnetic energy to mechanical motion through impact.
Solution Approach 2:
The patent replaces traditional mechanical transmission systems (gears, belts, lubrication) with a direct electromagnetic-to-mechanical conversion system. The electromagnetic hammer strikes a piston or rotor directly, eliminating the need for intermediate mechanical components that require maintenance and are sensitive to environmental conditions.
2Force
If tight seals, gears, or lubrication are used to enable high force output, then force capability is improved, but device complexity increases and maintenance requirements increase
Solution Approach 1:
The invention extracts and removes the complex mechanical transmission components (gears, tight seals, lubrication systems) that traditionally been used to achieve high force output. The electromagnetic hammer mechanism generates high force directly through impact, eliminating the need for these complex intermediate components.
Solution Approach 2:
The patent substitutes traditional mechanical force multiplication systems with a direct electromagnetic impact system. The electromagnetic hammer converts electrical energy directly to high-force mechanical impact, simplifying the overall system architecture while maintaining or enhancing force capabilities.
3Force
If the prime mover's displacement and force capabilities are limited by characteristic dimensions, then the actuator size is constrained, but the impact driven actuator can provide large displacements and higher forces
Solution Approach 1:
The invention employs periodic impact cycles where the electromagnetic hammer repeatedly strikes the piston or rotor. Each impact delivers a high-force impulse, and the cumulative effect of multiple impacts achieves large displacements. This periodic action allows the system to overcome the limited stroke of the electromagnetic prime mover while generating high forces.
Solution Approach 2:
The rapid repeated impacts create a vibration-like motion that propels the piston or rotor through the cylinder. This vibrational mechanism allows the system to achieve displacements much larger than the electromagnetic hammer's own travel distance, effectively decoupling the prime mover size from the output displacement.
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 solution enables actuators to achieve large displacements and higher forces beyond the limitations of the prime mover, suitable for industrial automation, flow control, and motion control in extreme environments without the need for tight seals or lubrication.
Implementation Method 1
A hammer driven actuator uses the high-speed, low-force characteristics of an electro-mechanical or pneumatic prime mover to develop kinetic energy that is transformed through an impact or impulse
Implementation Method 2
When the resulting impact force is sufficient to overcome the friction force provided by the friction interface (5), relative motion of the output shaft (7) is generated
Implementation Method 3
The output shaft (7) is guided by a mounting flange (6) via a friction interface (5)
Implementation Method 4
When the resulting impact force is sufficient to overcome the friction force provided by the friction interface (5), relative motion of the output shaft (7) is generated
Data Source
AI summary
We claim a hammer driven actuator that uses the fast-motion, low-force characteristics of an electro-magnetic or similar prime mover to develop kinetic energy that can be transformed via a friction interface to produce a higher-force, lower-speed linear or rotary actuator by using a hammering process to produce a series of individual steps. Such a system can be implemented using a voice-coil, electro-mechanical solenoid or similar prime mover. Where a typical actuator provides limited range of motion or low force, the range of motion of a linear or rotary impact driven motor can be configured to provide large displacements which are not limited by the characteristic dimensions of the prime mover.