Magnetic Piston Spring Assembly for Reduced Complexity

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Solution Overview

Problem

Existing apparatuses requiring precise matching of piston springs and pistons for different variants increase complexity and part diversity, leading to errors and swarf formation during assembly due to press-fitting or riveting.

Innovation Solution

The use of a magnetic element in an assembly tool to attract and hold a piston spring to the piston, allowing for simplified assembly without precise pre-assembly and reducing the need for complex mechanical devices, with a magnetic field guiding the piston spring into place and avoiding jamming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If press-fitting or riveting is used to permanently fix the piston spring to the piston, then the fixed connection is maintained during operation, but the complexity of assembly increases and swarf is formed

Engineering Contradiction:

Improvefixed connectionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical fastening methods (press-fitting, riveting) with a magnetic field-based holding system. A magnet is integrated into the piston structure to hold the piston spring in position during assembly and operation without requiring permanent mechanical fasteners, thereby eliminating swarf formation and simplifying the assembly process while maintaining reliable connection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnet acts as an intermediary between the piston and piston spring, providing a non-contact holding force that maintains the fixed connection without requiring direct mechanical interference or permanent fastening elements, thus avoiding the complexity and harmful effects of traditional mechanical fastening methods

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If precise matching of piston springs and pistons is required for different variants, then the fixed connection is ensured, but the diversity of parts increases

Engineering Contradiction:

Improvefixed connectionVSAvoidpart diversity

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The magnetic holding system provides a universal solution that can accommodate different variants of pistons and piston springs without requiring precise matching or variant-specific fastening methods. The magnet can hold different spring types and piston configurations, reducing part diversity while ensuring reliable connection across all variants

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The magnetic field strength and magnet positioning can be adjusted to accommodate different piston spring variants, allowing the same basic assembly structure to work with multiple configurations without requiring precise matching or increasing part diversity

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If pre-assembly of piston and piston spring is performed, then the interface dimensional accuracy is improved, but the assembly time and complexity increase

Engineering Contradiction:

Improveinterface dimensional accuracyVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The magnet is pre-integrated into the piston structure during manufacturing, creating a ready-to-use holding system that automatically engages the piston spring during final assembly. This preliminary preparation eliminates the need for complex pre-assembly operations while ensuring proper positioning and dimensional accuracy

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The magnetic holding force automatically positions the piston spring with high precision during assembly, replacing the need for manual pre-assembly operations and complex mechanical positioning fixtures, thereby reducing assembly time while maintaining interface dimensional accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method reduces the complexity and cost of assembly, minimizes errors, and allows for standardization of parts, enabling a more efficient and reliable assembly process with reduced dimensional accuracy requirements and part diversity.

Implementation Method 1

the piston spring (5) can be held on the piston (4) by a magnetic field of a magnetic element (8)

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS11370403B2Unit having at least one piston with an associated piston spring

Publication Date: 2022.06.28 CONTINENTAL AUTOMOTIVE TECHNOLOGIES GMBH

AI summary

An apparatus having a housing, a cavity which is disposed in the housing and which at least in regions is configured as a bore in which at least one piston and one piston spring associated with the piston are received, wherein the piston spring in the bore when activating the piston in the operation of the apparatus is compressed by the piston. The piston spring is configured from a magnetic or magnetizable material, the piston is configured from a non-magnetic material, and an assembly unit which comprises the piston having the piston spring is provided, and in which the piston spring is held on the piston by a magnetic field.