Hydraulic Insert Valve Coil Assembly With Rotatable Plug Alignment
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Solution Overview
Problem
Existing electromagnetically actuated hydraulic built-in valves require complex alignment procedures for the plug-in part with electrical connections during assembly, involving significant effort and potential for misalignment.
Innovation Solution
The valve design incorporates a friction fit between the fastening flange and pole tube, allowing the coil body and fastening flange to rotate relative to each other, with a sealing ring providing a frictional connection that maintains alignment once set, enabling easy adjustment of the plug-in part's position relative to the magnet housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plug-in part is aligned perpendicular to the axial direction of the electromagnet, then the electrical connections can be made, but complex alignment procedures are required during assembly involving significant effort and potential for misalignment
Solution Approach 1:
The mounting flange is designed to be rotatable relative to the pole tube through a friction fit connection, allowing the plug-in part to be aligned at different angular positions during assembly. This dynamic capability enables the plug-in part to be oriented perpendicular to the axial direction while simplifying the alignment process, as the flange can be rotated to achieve the desired orientation without complex procedures.
Solution Approach 2:
The friction fit connection between the mounting flange and pole tube is designed with specific friction characteristics that allow easy rotation during alignment but maintain secure positioning once aligned. This parameter optimization enables significant reduction in assembly time and effort while preventing misalignment after the alignment is completed.
2Adaptability or versatility
If the mounting flange is firmly fixed to the pole tube, then alignment is maintained, but the plug-in part cannot be adjusted to different positions
Solution Approach 1:
The mounting flange is designed with a friction fit connection that provides controlled mobility. The friction force is optimized to allow intentional rotation and position adjustment during assembly, yet maintains sufficient holding force to prevent spontaneous movement or misalignment during operation. This dynamic design enables both position adaptability and alignment reliability.
Solution Approach 2:
The friction fit connection automatically maintains the aligned position once set, without requiring additional locking mechanisms or external forces. The friction force itself serves to hold the alignment, eliminating the need for separate fastening elements while preventing misalignment during normal operation.
3Ease of operation
If a press fit connection is used between the coil former and pole tube, then the coil former is securely held axially, but rotation between the components is prevented
Solution Approach 1:
The connection system is divided into two independent functional segments: a press fit connection between the coil former and pole tube that provides axial holding force, and a separate friction fit connection between the mounting flange and pole tube that enables rotation. This segmentation allows each connection to perform its specific function without interfering with the other, enabling both secure axial positioning and rotational capability.
Solution Approach 2:
The mounting flange acts as an intermediary component that rotates relative to the pole tube while the coil former remains axially secured. This intermediate element decouples the rotational function from the axial holding function, allowing the coil former to be securely held axially by the press fit while the mounting flange provides the necessary rotation capability for aligning the plug-in part.
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 simplifies the alignment process, ensuring secure angular positioning without requiring extensive manual effort, allowing customers to adjust the plug-in part's position as needed while preventing misalignment and ensuring the valve's operational integrity.
Implementation Method 1
the mounting flange is held on the pole tube by friction
Implementation Method 2
the coil former is pressed onto the pole tube
Implementation Method 3
a sealing ring providing a frictional connection that maintains alignment once set
Data Source
Figure 1
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Figure 4
AI summary
The invention relates to an electromagnetically actuated hydraulic inset valve with an inset bushing forming a valve housing, which can be installed in an inset bore of a valve block, and with an electromagnet forming a unit with the inset bushing, which has a magnet housing with a coil housing and with a mounting flange on which at least one mounting eye is formed, a pole tube and a coil body inserted into a free space between the pole tube and the coil housing, which comprises a winding and a pole disk extending radially between the pole tube and the magnet housing, wherein the winding and the pole disk are overmolded together with plastic with the additional formation of a plug-in part with electrical connections located outside the magnet housing.The built-in valve is characterized by the fact that the mounting flange is held to the pole tube by friction, that the coil former is pressed onto the pole tube, and that after complete assembly of all parts, the coil former together with the pole tube and the mounting flange are rotatable relative to each other. In this way, the plug-in component can be aligned even after assembly of the built-in valve without any loose parts or the possibility of the alignment changing.