Magnet Assembly Clamping Ring for Fuel Injector Solenoid
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Solution Overview
Problem
Existing magnet assemblies for servo valves in fuel injectors face high mechanical loads due to non-ideal plane-parallel contact surfaces, which complicates manufacturing and increases stress on residual air gap disks.
Innovation Solution
A clamping ring system is used to create a non-positive connection between the magnet core and residual air gap disc, allowing for radial clamping force distribution and compensation of geometric tolerances and temperature expansions, with the clamping ring supported by a counter surface that generates a resultant clamping force to press against the residual air gap disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the residual air gap disk is clamped between the magnet core and magnet sleeve, then the magnet assembly can be assembled, but the residual air gap disk is exposed to high mechanical loads due to non-ideal plane-parallel contact surfaces
Solution Approach 1:
The patent introduces a clamping ring as an intermediary element between the magnet core and magnet sleeve. This clamping ring distributes the clamping force uniformly across the contact surfaces, preventing localized stress concentrations that would otherwise occur due to manufacturing imperfections. The intermediary element transforms the direct contact interface into a multi-component interface that can better accommodate geometric tolerances.
Solution Approach 2:
The patent changes the clamping mechanism from direct contact to an indirect clamping system with adjustable parameters. The clamping ring can be designed with specific geometric parameters (thickness, diameter, material properties) that allow it to compensate for variations in the contact surfaces. This parameter adjustment capability enables the system to maintain adequate clamping force while reducing the mechanical load on the residual air gap disk.
2Stability of the object's composition
If high clamping forces are applied to position the magnet core clearly, then the magnet assembly becomes stable, but the residual air gap disk experiences increased mechanical stress
Solution Approach 1:
The patent segments the clamping function into two separate components: the clamping ring handles the radial clamping force to secure the magnet core position, while the counter surface handles the axial positioning. This segmentation allows each component to be optimized for its specific function, distributing the mechanical stress away from the residual air gap disk while maintaining magnet core stability.
Solution Approach 2:
The patent employs a conical counter surface instead of a flat surface. This curved geometry allows the clamping ring to be positioned radially while automatically generating the necessary axial clamping force through the inclined surface. The curvature transforms radial positioning into axial clamping, stabilizing the magnet core without requiring direct axial loading of the residual air gap disk.
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 solution reduces the manufacturing tolerance requirements for the magnet core and sleeve, effectively managing mechanical loads and ensuring reliable operation by maintaining a stable residual air gap, thus enhancing the durability and performance of the magnet assembly.
Implementation Method 1
a clamping ring (60) with a radial clamping force with which the clamping ring (60) is supported on the counter surface (52) and with which a resulting clamping force is derived against the residual air gap disc (40)
Implementation Method 2
Magnetic actuators have a magnet assembly with a magnet core (21) and a magnet armature (22)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a magnet assembly, particularly for a solenoid valve of a fuel injector, having a magnetic core (21) and an armature (22). On one end face (23), on the armature plate side, the magnetic core (21) has an inner pole surface (24a) and an outer pole surface (25a). A residual air gap disc (40) is arranged between the magnetic core (21) and the armature (22), said residual air gap disc being held on the armature plate-side end face (23) of the magnetic core (21) by means of a clamping connection (50). The clamping connection (50) has a tension ring (60) which presses the residual air gap disc (40) against the armature plate-side end face (23) of the magnetic core (21).