Magnetic Core Bulge for Centering Electromagnetic Devices
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Solution Overview
Problem
Conventional electromagnetic devices require high manufacturing accuracy to avoid oblique positions of the magnetic core, leading to increased electromagnetic losses and reduced efficiency.
Innovation Solution
The electromagnetic device features a magnetic core with a bulge on its surface, allowing for easy centering within the housing, which reduces manufacturing tolerances and ensures uniform magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high manufacturing accuracy is used to center the magnetic core, then the orientation precision is improved, but the production complexity and time increase
Solution Approach 1:
The magnetic core is pre-centered on the insertion axis before final assembly into the housing. This preliminary centering action eliminates the need for complex post-assembly adjustments and ensures accurate orientation without requiring high-precision machining of all components.
Solution Approach 2:
The magnetic core design includes self-centering features such as tapered surfaces or positioning elements that automatically align the core with the housing during insertion. This self-centering mechanism eliminates the need for external centering devices or complex alignment procedures.
2Loss of energy
If high manufacturing accuracy is used to avoid oblique positions, then the electromagnetic efficiency is improved, but the production time increases
Solution Approach 1:
The magnetic core is pre-centered and fixed in its correct orientation before the coil is wound around it. This preliminary positioning ensures that the magnetic core will be in the correct position during final assembly, eliminating the need for time-consuming post-assembly adjustments and ensuring optimal electromagnetic efficiency from the start.
Solution Approach 2:
The magnetic core includes self-aligning features that automatically ensure correct orientation during assembly, eliminating the need for complex alignment procedures and reducing production time while maintaining low electromagnetic losses.
3Manufacturing precision
If high manufacturing accuracy is used for the magnetic core and housing, then the centering precision is improved, but the manufacturing cost increases
Solution Approach 1:
The magnetic core is pre-centered and secured to the insertion axis before final assembly. This preliminary action allows the use of simpler, less precise housing components since the critical centering has already been accomplished during the pre-assembly stage, reducing overall manufacturing costs.
Solution Approach 2:
The magnetic core design incorporates self-centering features that eliminate the need for high-precision housing bore machining. The self-centering mechanism compensates for variations in housing manufacturing tolerances, allowing the use of simpler, more cost-effective manufacturing processes for the housing while still achieving high centering precision.
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 design enables the production of electromagnetic devices with lower manufacturing tolerances, resulting in reduced electromagnetic losses, improved efficiency, and more uniform magnetic properties.
Implementation Method 1
An electromagnetic actuator has a coil element which comprises a magnetic core and a coil body arranged around the magnetic core and which has a coil which is arranged circumferentially around the coil body and has a coil winding
Implementation Method 2
The magnetic core has a first region and a second region. The coil body is arranged circumferentially around the second region of the magnetic core
Data Source
AI summary
An electromagnetic device including: a magnetic core with a longitudinal axis, which magnetic core has a first region and a second region; a coil body arranged circumferentially around the second region of the magnetic core and has at least one receiving region for receiving at least one coil winding of a coil; and a housing made of a magnetic material, which housing circumferentially surrounds the magnetic core and the coil body and has at least one contact region in which the housing surrounds/contacts the magnetic core. The first region of the magnetic core has at least one bulge on a surface of the magnetic core facing the contact region of the housing, the bulge being configured such that the magnetic core does not contact the housing in a portion along the longitudinal axis between the bulge and the second region.