Integrated Sheet Metal Casing Electromagnet Design
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Solution Overview
Problem
The production of electromagnets with high precision and low hysteresis in large quantities is costly due to the need for multiple components in the iron circuit, which generate unwanted magnetic resistance at each flux transition, leading to inconsistent characteristic curves.
Innovation Solution
The electromagnet design minimizes components by using a sheet metal casing produced through various processes such as stamping, sintering, machining, or metal injection molding, with a non-cylindrical magnetic pole formed by protruding and recessed zones, eliminating the need for mechanical reworking and reducing magnetic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are used in the iron circuit (yoke, yoke disc, casing, cone), then the electromagnet can be assembled from standardized parts, but each transition generates magnetic resistance and increases tolerance-related spread in characteristic curves
Solution Approach 1:
The patent merges multiple iron circuit components (casing and cone) into a single integrated sheet metal casing. The casing is formed with an extended portion that directly creates the conical magnetic pole shape, eliminating the need for separate cone components and their associated magnetic flux transitions. This reduces magnetic resistance while maintaining manufacturing efficiency.
Solution Approach 2:
The sheet metal casing is divided into functional zones: a cylindrical casing portion for structural support and an extended conical portion for magnetic pole formation. This segmentation within a single component allows optimization of each zone's function while avoiding the drawbacks of multiple assembled parts.
2Productivity
If conventional stamping and forming processes are used for the sheet metal casing, then production is efficient, but mechanical reworking is required to achieve sufficient precision for the magnetic pole
Solution Approach 1:
The magnetic pole geometry is pre-formed during the initial stamping and forming processes. The sheet metal casing is designed with the conical magnetic pole extension integrated into the forming die, so the precise geometry is created in the primary forming operation rather than requiring subsequent mechanical reworking.
Solution Approach 2:
The patent modifies the forming process parameters and die design to directly produce the complex conical magnetic pole geometry. By adjusting forming pressures, temperatures, and die configurations, the process achieves sufficient precision for magnetic pole formation without requiring additional mechanical reworking steps.
3Ease of manufacture
If granular iron is used for sintering the sheet metal casing, then production costs are reduced, but achieving sufficient precision without mechanical reworking is challenging
Solution Approach 1:
The sintering process parameters (temperature, pressure, time, atmosphere) are optimized to achieve precise dimensional control of the conical magnetic pole extension. By carefully controlling these parameters, the granular iron sintering process produces the required geometric precision without mechanical reworking, maintaining cost advantages.
Solution Approach 2:
The use of granular iron as a sintering feedstock creates a composite microstructure in the final casing. This composite structure, formed from controlled granular material, allows achievement of precise geometry through optimized sintering while maintaining cost-effectiveness compared to machining solid material.
4Ease of manufacture
If the magnetic pole has a conventional cylindrical form, then manufacturing is simple, but the force-stroke curve cannot be optimized
Solution Approach 1:
The magnetic pole is designed with non-uniform local geometry: a conical extension with specific angular dimensions (30-60 degrees) protruding from the cylindrical casing. This local geometric variation optimizes the magnetic flux distribution and force-stroke characteristics in the critical magnetic pole region while keeping the main casing structure simple and easy to manufacture.
Solution Approach 2:
The magnetic pole geometry transitions from a symmetric cylindrical casing to an asymmetric conical extension. This asymmetric shape is specifically designed to optimize the force-stroke curve by controlling magnetic flux density distribution, creating better actuation performance while maintaining manufacturing simplicity through integrated forming.
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 approach reduces production costs and variability in electromagnet performance by minimizing parts and achieving precise forming without mechanical reworking, enhancing the force-stroke curve and enabling efficient actuation of valves, couplings, or reciprocating pumps.
Implementation Method 1
An electromagnet (1) includes at least one magnetic coil (2), one yoke (5), one magnet keeper (3) and one iron backplate (4)
Implementation Method 2
the sheet metal casing (7) is produced from a circular blank as a result of a stamping and forming process
Implementation Method 3
the sheet metal casing is produced from granular iron as a result of a sintering process
Implementation Method 4
Each transition of the magnetic flux from one component to another generates a magnetic resistance
Data Source
AI summary
An electromagnet and method for producing an electromagnet. The electromagnet includes a sheet metal casing encompassing a magnetic coil at its end face on a magnetic pole side and extends into an interior of the magnetic coil and forms, in this case, a magnetic pole which interacts with a magnet keeper. The electromagnet enables actuation of a valve, a coupling or a reciprocating pump. The structure is achieved with as few cutting processes as possible to be used for generating the individual parts and as small a number as possible of individual parts is to be used per electromagnet.