Integrated Plastic Housing for Electromagnetic Actuator Cost Reduction
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Solution Overview
Problem
The existing electromagnetic actuating devices for valve trains in internal combustion engines are costly due to the separate components and complex assembly, particularly the metal enclosures and connectors, which increase production costs and installation complexity.
Innovation Solution
The integration of the plug-in connector and connecting flange as integral parts of the top housing made of plastic, encapsulating the solenoid device, eliminates the need for a metal sleeve enclosure and allows for a unified plastic element, reducing production costs and simplifying installation by using a metal sleeve encapsulated in plastic for sealing and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate metal components (plug-in connector, connecting flange, metal sleeve) are used in the actuating device, then structural strength and electrical connectivity are ensured, but production costs and assembly complexity increase
Solution Approach 1:
The patent combines the plug-in connector, connecting flange, and metal sleeve into a single integrated plastic housing component. This merging eliminates multiple separate parts and assembly steps while maintaining the required structural and electrical functions through the integrated design of the plastic element.
Solution Approach 2:
The plastic housing component performs multiple functions simultaneously: it provides structural enclosure, integrates electrical connection points via the plug-in connector, provides mounting surfaces via the connecting flange, and ensures sealing via the metal sleeve interface. This multi-functionality reduces the overall component count.
2Reliability
If a metal sleeve enclosure is used to protect the solenoid device, then protection and sealing are improved, but production costs and installation space increase
Solution Approach 1:
The patent uses a composite structure combining plastic and metal elements. The plastic housing provides the primary enclosure and cost advantage, while an integrated metal sleeve provides the necessary sealing and protection for the solenoid device. This composite approach balances protection requirements with cost and space efficiency.
3Volume of moving object
If multiple solenoid devices and adjusting pins are arranged in a compact configuration, then installation space is reduced, but manufacturing precision and alignment requirements increase
Solution Approach 1:
By integrating the plug-in connector and connecting flange into the plastic housing, the patent reduces the overall number of components that require precise alignment. The unified plastic element provides built-in alignment features and mounting surfaces that simplify the positioning of multiple solenoid devices and adjusting pins in a compact arrangement.
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 integration reduces production costs and installation space while maintaining effective sealing and functionality, especially beneficial for multifunctional actuating devices with multiple solenoid devices and adjusting pins, allowing for compact and cost-effective assembly.
Implementation Method 1
an electrically energizable solenoid device is embedded in the top part of the housing and an adjusting pin that is actuated by the solenoid device is mounted in the bottom part of the housing so as to move longitudinally
Data Source
AI summary
An electromagnetic actuating device is being proposed for a valve train that can be adjusted on the cam side in an internal combustion engine, including a housing with a top part and a bottom part, whereby an electrically energizable solenoid device is embedded in the top part of the housing and an adjusting pin that is actuated by the solenoid device is mounted in the bottom part of the housing so as to move longitudinally, and also including a plug-in connector that is made of plastic and that runs on the top part of the housing in order to supply electricity to the solenoid device as well as a connecting flange that runs on the housing in order to attach the actuating device to the internal combustion engine. The plug-in connector and the connecting flange are integral parts of the top part of the housing made by encapsulating the solenoid device with plastic.