Multi-Stage Spring Assembly for Solenoid Valve Control
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Solution Overview
Problem
Solenoid-actuated valves face challenges in precise control of the movable armature due to the linearly proportional spring force and inversely proportional magnetic force, making it difficult to achieve precise positioning and varying force requirements during different stages of actuation.
Innovation Solution
A spring assembly with multiple flexing segments and a contact member featuring steps that allow for distinct actuation stages, providing a first biasing force during the initial movement and a higher second biasing force by restricting further flexing of the first segments, allowing the second segments to continue flexing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a linear spring force is used to bias the movable armature, then the spring provides a simple and reliable biasing mechanism, but the control precision of the movable armature deteriorates due to the mismatch between linear spring force and inverse-square magnetic force
Solution Approach 1:
The spring is divided into multiple flexing segments (first flexing segments and second flexing segments) that can independently flex during different actuation stages. This segmentation allows the spring to provide different biasing forces at different positions of the movable armature, improving control precision while maintaining the simplicity of a mechanical biasing mechanism
Solution Approach 2:
Different segments of the spring are designed with different flexing characteristics. The first flexing segments provide a first biasing force during initial actuation, while the second flexing segments provide a second biasing force during subsequent actuation. This local differentiation in flexing properties enables precise control at different positions without complicating the overall mechanism
2Device complexity
If a single spring configuration is used throughout the actuation range, then the device structure remains simple, but the ability to accommodate varying force requirements at different actuation stages is limited
Solution Approach 1:
The spring structure is segmented into multiple flexing segments that can independently deform. This allows the spring to adapt its force profile to different actuation stages while maintaining a relatively simple overall structure without requiring multiple separate springs or complex adjustment mechanisms
Solution Approach 2:
The spring transitions from a static, uniform structure to a dynamic system where different segments can flex independently based on the actuation stage. This dynamic behavior allows the spring to provide varying biasing forces at different positions of the movable armature, enhancing adaptability without significantly increasing structural complexity
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 non-linear changes in biasing forces across actuation stages, enhancing control precision and accommodating varying load conditions, such as requiring higher current for further armature movement, and can be applied to valves or shock absorbers.
Implementation Method 1
The energized solenoid generates a magnetic field. The magnetic field operates on a movable armature connected to a valve member.
Implementation Method 2
the solenoid comprises an electric current that passes through an electromagnetic coil
Implementation Method 3
the spring assembly comprises a spring including one or more first flexing segments and one or more second flexing segments
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
A spring assembly (220) is provided. The spring assembly (220) includes a spring (221) with one or more first flexing segments (330a-330d) and one or more second flexing segments (331a-331d). The spring assembly (220) further includes a contact member (222) including a plurality of steps (223-225). The plurality of steps can contact at least a portion of the spring (221) such that the first and second flexing segments (330a-330d, 331a-331d) can flex during a first actuation stage thereby providing a first biasing force and at least one of the first flexing segments (330a-330d) is prevented from flexing further during a second actuation stage to provide a second biasing force.