MR Damper Piston Core Segmentation for Easier Coil Assembly
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Solution Overview
Problem
The existing MR damper piston designs have restricted spaces for electrical connections between lead wires and coils, making assembly and electrical connections difficult, which hampers assemblability and productivity.
Innovation Solution
The piston design features a separable core with an upper and lower core, a magnetic field generator with an insulator, and a coil connection terminal system, including side coil guides and terminal insertion grooves, facilitating easier assembly and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a core is configured as one member, then the magnetic circuit structure is simple, but the space for electrical connection is restricted and assembly becomes difficult
Solution Approach 1:
The core is divided into an upper core and a lower core that can be assembled separately. The lower core includes a lower core body and a central protrusion, while the upper core has a side opening. This segmentation allows the coil to be wound around the lower core body and then assembled with the upper core, providing adequate space for electrical connection and significantly improving assembly ease.
2Device complexity
If a core is configured as one member, then the magnetic circuit structure is simple, but electrical connection operation becomes difficult
Solution Approach 1:
By dividing the core into upper and lower sections with a side opening in the upper core, the design provides accessible space for lead wire insertion and electrical connection operations. The coil can be properly positioned and connected before final assembly, making electrical connection operations straightforward.
3Ease of manufacture
If the core structure is simplified, then manufacturing is easier, but productivity is reduced due to difficult assembly
Solution Approach 1:
The segmented core structure with side opening enables parallel assembly operations - the coil can be wound and electrically connected to the lower core body while the upper core is prepared separately, then quickly assembled together. This significantly improves assembly productivity compared to attempting to perform all operations on a single-piece core.
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 enhances assemblability and electrical connection efficiency, improving the assembly process and overall productivity of the MR damper piston.
Implementation Method 1
a coil (132) wound around the body (131A) of the insulator (131)
Implementation Method 2
a magneto-rheological (MR) damper using magneto-rheological fluid is used
Data Source
AI summary
A piston for a magneto-rheological (MR) damper includes an upper core 11 having a side opening 113; a lower core 12 having a lower core body 121 and a central protrusion 122 protruding upwardly from the lower core body 121; and a magnetic field generator 13 coupled to the central protrusion 122, including a body 131A around which a coil 132 is wound, a ring-shaped upper support 131B extending from the upper portion of the body 131A in the radial direction, and a ring-shaped lower support 131C extending from the lower portion of the body 131A in the radial direction.