Magnet Carrier Assembly Locking Collar Design
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Solution Overview
Problem
Current magnet carrier assemblies for automotive applications require complex and costly manufacturing processes, specialized tools for assembly, and increased complexity as shaft size decreases, due to the need for threaded openings and mechanical fastening.
Innovation Solution
A magnet carrier assembly with a carrier housing, magnet holder, shaft holder, and flexible fingers, secured by a locking collar that can be easily assembled without specialized tools, reducing manufacturing complexity and requiring less space, using a one-piece design with a reliable locking feature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fastening with bolts and threaded openings is used to attach the magnet carrier to the valve shaft, then the connection strength is improved, but the manufacturing complexity and cost increase due to specialized machining requirements
Solution Approach 1:
The patent replaces the traditional mechanical fastening system (bolts, threaded openings, specialized tools) with a friction-based interference fit system. The magnet carrier is press-fitted directly onto the valve shaft, eliminating the need for threaded holes and complex mechanical fasteners. This substitution reduces manufacturing complexity while maintaining connection strength through proper material selection and interference fit design.
2Reliability
If threaded openings and mechanical fasteners are used in the valve shaft, then the attachment reliability is improved, but the ease of manufacture deteriorates due to additional machining operations
Solution Approach 1:
The patent extracts and eliminates the threaded opening and mechanical fastener components from the assembly process. By designing the magnet carrier to be directly press-fitted onto the smooth valve shaft surface, the invention removes the need for machining threaded holes and using separate fastener components, thereby improving ease of manufacture while maintaining attachment reliability through the interference fit connection.
3Volume of moving object
If the shaft size is decreased to reduce space requirements, then the compactness is improved, but the ability to achieve required connection strength and machining feasibility deteriorates
Solution Approach 1:
The patent replaces the mechanical fastening system that requires large threaded openings with a friction-based interference fit system. This allows the magnet carrier to be securely attached to smaller diameter valve shafts without compromising connection strength, as the interference fit generates sufficient friction force to transmit torques and loads even on compact, small-diameter shafts.
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
The solution simplifies assembly, reduces manufacturing complexity, and provides a reliable locking mechanism with low insertion force and high retention force, suitable for applications with space limitations, while eliminating the need for specialized tools and complex machining.
Implementation Method 1
The collar is further moved to a locked position to lock the carrier assembly to the shaft
Implementation Method 2
retracting the locking collar longitudinally from the rear end of the shaft holder portion toward a front end to an open position to allow the fingers to flex outward
Data Source
AI summary
A carrier assembly for attaching a magnet to a shaft of a valve assembly includes a carrier housing having a magnet holder portion, a shaft holder portion, and a plurality of fingers extending from the shaft holder portion. The carrier assembly includes a locking collar wherein the collar is installed over the carrier housing and moved from a open position to a closed position. The collar is further moved to a locked position to lock the carrier assembly to the shaft.