Electromagnetic Injection Valve Magnetic Circuit Design
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Solution Overview
Problem
Existing electromagnetic injection valves face challenges in achieving high magnetic performance while maintaining low production costs, particularly under high fuel pressure conditions, and are affected by air gaps in the magnetic flux path.
Innovation Solution
The design incorporates an upper and lower magnetic ring with a housing part that includes axial cuts to prevent eddy currents, allowing the use of high-performance magnetic materials and reducing costs through forming processes, ensuring close contact and eliminating air gaps for improved magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-performance magnetic materials are used in the housing, then magnetic performance is improved, but manufacturing cost increases
Solution Approach 1:
The housing is divided into two distinct parts: an upper housing part made of magnetic material and a lower housing part made of non-magnetic material. This segmentation allows each part to be optimized for its specific function while using cost-effective materials overall, resolving the contradiction between magnetic performance and manufacturing cost.
Solution Approach 2:
Magnetic material is applied locally only where it is functionally required (upper housing part and magnetic rings), while non-magnetic material is used in other areas (lower housing part). This local quality approach ensures magnetic performance is maintained in critical areas while reducing overall material costs.
2Ease of manufacture
If air gaps are present in the magnetic flux path, then manufacturing is easier, but magnetic performance deteriorates
Solution Approach 1:
A lower magnetic ring is introduced as an intermediary component between the valve body and the lower housing part. This magnetic ring acts as a mediator that bridges the gap, ensuring continuous magnetic flux path while maintaining ease of assembly through press-fit connections.
Solution Approach 2:
The lower magnetic ring is pre-positioned on the valve body through press-fit before final assembly with the housing parts. This preliminary action ensures proper alignment and eliminates air gaps in advance, facilitating easier final assembly while guaranteeing magnetic performance.
3Manufacturing precision
If the housing is machined to create pockets for coil and tubes, then assembly precision is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is segmented into upper and lower parts that can be manufactured separately using simpler processes, then assembled together. This segmentation reduces the complexity of machining complex pockets while maintaining assembly precision through standardized connection interfaces.
Solution Approach 2:
Multiple functional elements (coil housing, tube mounting, magnetic flux path) are merged into the modular housing structure where the upper and lower parts come together. This merging approach simplifies individual component manufacturing while achieving precise overall assembly through the modular design.
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 enhances magnetic performance, enabling operation under high fuel pressures (up to 250-500 bar) and reduces costs by utilizing cost-effective materials and processes, while maintaining efficient electromagnetic field guidance.
Implementation Method 1
The valve needle may be actuated by an electromagnetic actuation unit
Implementation Method 2
The lower magnetic ring (15) is positioned on the valve body (3) in such a way that an upper side (31) of the lower magnetic ring (15) is in close contact with an underside (33) of the housing part (17)
Implementation Method 3
an upper magnetic ring (13) press-fitted with the inlet tube (7) or the valve body (3); a lower magnetic ring (15) press-fitted with the valve body (3)
Implementation Method 4
The housing part (17) and/or the lower magnetic ring (15) comprise at least one cut (23, 25) which extends in axial direction
Data Source
AI summary
The present disclosure relates to internal combustion engines. Various embodiments may include an electromagnetic injection valve, particularly a solenoid type fluid injection valve for automotive applications. For example, an electromagnetic injection valve may include: an inlet tube; a valve body having a longitudinal axis and a cavity in which a valve needle moves; an upper magnetic ring press-fitted with the inlet tube or the valve body; a lower magnetic ring press-fitted with the valve body; and a housing part surrounding an electromagnetic actuator unit for moving the valve needle. The lower magnetic ring is positioned on the valve body in such a way that an upper side of the lower magnetic ring is in close contact with an underside of the housing part. The electromagnetic actuator unit abuts the upper magnetic ring and the lower magnetic ring on opposite axial sides. The housing part and/or the lower magnetic ring comprises a cut extending along the axis.