Magnetic Valve Module for Low-Pressure Pilot Air Operation
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Solution Overview
Problem
Conventional color-change valve devices face challenges in being compact while maintaining efficient operation with low pilot air pressure, as they require increased pressure due to smaller piston diameters, and have durability issues due to direct magnet contact and dimensional variations affecting performance consistency.
Innovation Solution
The design incorporates a magnetic-attraction force between permanent magnets with a controlled clearance to drive the piston, using a first and second magnet holder to secure and align the magnets, allowing for low-pressure operation and reduced risk of direct contact, while ensuring uniform magnetic force through precise alignment and housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the valve device is downsized to be compact, then the device size is reduced, but the pilot air pressure must be increased to maintain sufficient driving force
Solution Approach 1:
A permanent magnet is introduced as an intermediary component between the piston and the driving force source. The permanent magnet generates a magnetic field that acts on a ferromagnetic plate attached to the piston, creating a magnetic driving force that supplements the pilot air pressure. This allows the valve device to maintain sufficient driving force with reduced pilot air pressure while keeping the compact size.
2Force
If permanent magnets are placed close together to increase magnetic attraction force, then the driving force is improved, but the risk of direct contact and damage increases
Solution Approach 1:
A ferromagnetic plate is introduced as an intermediary between the permanent magnet and the piston. The permanent magnet generates magnetic force that acts on the ferromagnetic plate, which in turn drives the piston. This indirect magnetic coupling allows the permanent magnet to be positioned close to the piston for strong magnetic attraction while preventing direct contact, thereby protecting the permanent magnet from damage and improving reliability.
3Volume of moving object
If the piston diameter is reduced to downsize the valve, then the device becomes more compact, but the pressurized area decreases requiring higher pressure
Solution Approach 1:
The permanent magnet and ferromagnetic plate system acts as a force amplifier that compensates for the reduced pressurized area. By positioning the permanent magnet close to the ferromagnetic plate on the piston, a strong magnetic attraction force is generated that supplements the force from the reduced-area piston, allowing the valve to maintain sufficient total driving force while keeping the compact size.
4Ease of manufacture
If dimensional variations of components are not controlled, then manufacturing is easier, but performance consistency deteriorates
Solution Approach 1:
The permanent magnet and ferromagnetic plate configuration creates a magnetic field interaction that is relatively insensitive to small dimensional variations. The magnetic field naturally distributes and adapts to slight variations in component dimensions, providing a self-compensating effect that maintains consistent magnetic driving force across multiple units without requiring extremely tight manufacturing tolerances.
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 configuration enables the color-change valve to operate with relatively low pilot air pressure, enhances durability by avoiding direct magnet contact, and minimizes performance variations among products by securing and aligning the magnets effectively.
Implementation Method 1
a magnetic-attraction force acts between both permanent magnets, and drives the piston in the first direction
Data Source
AI summary
This invention provides a valve-module that is operative with relatively low-pressure pilot-air despite its small size and has excellent durability with less performance-variations than among other similar products. The valve-module of the present invention includes a pilot-port and a biasing-means for biasing the piston-portion in the opposite direction, and controls the opening and closing of the valve by supplying and discharging pilot-air. The first-permanent magnet is held by the first magnet-holder of the valve-rod, and the second-permanent magnet is held by the second magnet-holder of the piston housing. A magnetic-attraction force acts between both permanent magnets and drives the piston in the first direction and increases with the mutual approach of both magnets. Due to the presence of the thin-walled first-and-second collision-avoidance portions, an arrangement-relationship is set between the two permanent magnets such that the end-faces do not directly collide with each other, even when they are closest to each other.