Hydraulic Valve Actuator with Nested Rod Support
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Solution Overview
Problem
Existing hydraulic valve actuators for cam phasers require significant installation space due to their axial length, which limits their application in compact systems, and they often require additional components for support, increasing friction and costs.
Innovation Solution
The actuator design features a magnetisable housing with a pole group and armature that uses a rod-rod support mechanism, where the armature is axially movable and supported by a rod that penetrates through its entirety, with a cavity between the armature and rod to reduce installation space and weight, while maintaining high force density by minimizing air gaps and optimizing magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rod-rod support mechanism is used with a rod penetrating the entire armature, then friction is reduced and service life is extended, but the axial length and installation space requirements increase
Solution Approach 1:
The rod bearing is nested within the cavity of the armature, allowing the support structure to be contained within the existing component volume rather than extending externally. This resolves the contradiction by providing rod-rod support functionality without increasing the overall axial length of the actuator.
Solution Approach 2:
The rod bearing is positioned in a radial cavity within the armature rather than extending axially outward. This dimensional repositioning allows the support function to be achieved in the radial direction while maintaining compact axial dimensions, thus reducing installation space requirements.
2Reliability
If the armature is supported on the rod over the entire axial extension of the rod, then friction is minimized, but additional support components increase device complexity
Solution Approach 1:
The rod bearing function is merged with the existing armature and terminal cover components. The cavity in the armature and the corresponding features in the terminal cover are integrated to form the complete rod support structure, eliminating the need for separate support components while maintaining low friction through full axial contact.
3Length of moving object
If the cavity between armature and rod is used to receive terminal cover or support disc, then installation space is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The rod support function is segmented between two locations: the cavity in the armature and the terminal cover or support disc. This segmentation allows each component to be manufactured independently with standard tolerances, reducing the cumulative precision requirements compared to a single integrated support structure.
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 results in a compact, lightweight actuator with high force density, optimized installation space, and reduced friction, enabling reliable operation in small spaces while maintaining nearly constant magnetic force compared to prior art.
Implementation Method 1
a magnetisable actuator housing (14) that envelops a magnet coil (16)... an armature (40) which is received axially movable in an inner space of the pole group (24)... wherein an armature force caused by running current through the actuator can be transferred to the hydraulic valve
Data Source
AI summary
An actuator for a hydraulic valve for a cam phaser, the actuator comprising a magnetisable actuator housing that envelops a magnet coil; a pole group that is arranged in a housing receiver opening of the magnetisable actuator housing, wherein the pole group includes a pole core and a pole tube, wherein the pole core and the pole tube are connected by a connection bar and the pole core is connected with the connection bar by a pole core cone, or the pole tube is connected with the connection bar by a pole tube cone, wherein an armature is received axially movable in an inner space of the pole group.