Multi-Stage Actuator Assembly for Extended Axial Stroke
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Solution Overview
Problem
Existing actuator assemblies face challenges in achieving a lightweight, compact, and reliable design due to the logarithmic decrease in attractive force with increasing gaps between coils and armatures, necessitating a solution that balances size and efficiency demands.
Innovation Solution
A multi-stage actuator assembly featuring independently energizable coils and armatures, where a first coil drives the component a predetermined distance in one energized state and both coils drive it further in a second state, allowing for increased axial stroke while maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the size of the coil is increased to close larger gaps, then the attractive force is improved, but the weight and dimensions of the actuator assembly increase
Solution Approach 1:
The actuator assembly is divided into multiple stages with separate coil-armature pairs. Each stage has its own coil and armature that can be independently controlled, allowing the system to achieve larger total stroke through sequential activation of multiple stages rather than requiring a single large coil with excessive weight
2Force
If the size of the coil is increased to close larger gaps, then the attractive force is improved, but the dimensions of the actuator assembly increase
Solution Approach 1:
The second armature is slidably received within the armature housing that contains the first armature, creating a nested configuration. This allows multiple armatures to occupy overlapping spatial volumes, reducing the overall axial length of the actuator assembly while maintaining the capability for extended total stroke through sequential activation
3Ease of operation
If a single coil-armature pair is used, then the structure is simple, but the axial stroke is limited
Solution Approach 1:
The second armature is designed to slide within the armature housing, transitioning between retracted and extended positions based on the energization state of the second coil. This dynamic configuration allows the actuator to achieve variable total stroke lengths depending on which stages are activated, maintaining structural simplicity while enabling extended axial movement
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 multi-stage actuator assembly effectively increases the axial stroke by up to 180%-220% of the initial distance, achieving a more efficient and compact design that addresses the limitations of traditional actuators.
Implementation Method 1
Actuator assemblies with electromagnetic arrangements are well known. Actuator assemblies typically include a coil and an armature. These known actuators energize the coil to attract the associated armature.
Data Source
AI summary
An actuator assembly is disclosed. The actuator assembly includes a driven component, a coil housing including a first coil and a second coil, and an armature housing including a first armature and a second armature. The first armature is axially fixed to the armature housing, and the second armature is slidably received within the armature housing and axially fixed to the driven component. In a first energized state, the first coil is energized, and the driven component is driven a first predetermined distance towards the coil housing. In a second energized state, the first coil and the second coil are energized, and the driven component is driven a second predetermined distance towards the coil housing.