Multi-Valve Venting Channel Layout for Simpler Overmolding
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Solution Overview
Problem
The existing multi-valve devices for electronically regulated air spring systems in vehicles require a complex two-stage overmolding process and excessive copper for coil elements, making production cumbersome and costly.
Innovation Solution
The solution involves forming a modular venting collection channel using plastic injection molded venting channel elements that connect to the cores' venting bores, eliminating the need for a housing cover and allowing a single overmolding process to create a monolithic housing body, thereby reducing copper usage and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a two-stage overmolding process is used to produce the housing with integrated coil carriers and venting collection channel, then the housing can be produced as a single integrated component, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The housing production is divided into two separate one-shot overmolding processes: first producing the housing body with coil carriers, then separately producing the venting collection channel and connecting it. This segmentation resolves the contradiction by avoiding complex multi-stage overmolding while achieving integration through simpler sequential processes.
Solution Approach 2:
The coil carriers are pre-assembled with the housing body in the first overmolding process before the venting collection channel is added. This preliminary action allows the housing structure to be prepared in advance, simplifying the overall manufacturing process while maintaining integration.
2Reliability
If a cover is used to bound the venting collection channel, then the venting channel can be sealed and protected, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The venting collection channel is merged with the housing body through the connecting element, forming an integrated assembly. This eliminates the need for a separate cover to bound the venting channel, reducing the number of parts while maintaining sealing through the integrated design and sealing elements.
Solution Approach 2:
A connecting element acts as an intermediary between the housing body and the venting collection channel, providing both mechanical connection and sealing function. This intermediary component replaces the need for a separate cover while ensuring proper sealing of the venting channel.
3Power
If extensive copper is used for coil elements, then sufficient magnetic field strength is achieved for reliable valve actuation, but material cost and weight increase
Solution Approach 1:
The coil carrier design incorporates optimized geometric parameters and material properties that enhance magnetic field generation efficiency. By changing the design parameters of the coil carrier and coil element configuration, sufficient magnetic field strength is achieved with reduced copper quantity, resolving the contradiction between power output and material usage.
4Ease of manufacture
If multiple separate components are used for venting channel elements, then manufacturing and assembly are simplified, but the number of parts increases
Solution Approach 1:
Multiple venting channel elements are merged into a single integrated venting collection channel component. This integration maintains the manufacturing advantages of modular design while reducing the final part count, as the elements are combined into one piece that can be directly installed with the housing body.
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 approach reduces the complexity and cost of production by eliminating the need for a housing cover and minimizing copper usage while maintaining or improving displacement force, and enhances mechanical stability through a monolithic housing body.
Implementation Method 1
electromagnetic valve actuators, each having coil elements arranged in the housing in a stationary manner, a core arranged in the housing, and armature elements, which can be displaced along a displacement axis in the housing relative to the core and to a (respective) pneumatic connection of the housing as a response to energization of the coil elements
Data Source
AI summary
A pneumatic multi-valve device includes a housing (21) having a plurality of electromagnetic valve actuators (1), each having coil elements (2) arranged stationary in the housing (21), a core (4) arranged in the housing (21), and armature elements (24). The cores (4) each have a venting bore (5) connected to a venting collection channel (14) on the side of the cores (4) facing away from the connection housing side (23). The venting collection channel is connected to a venting opening (28) of the housing (21), which venting opening is arranged on a housing side different from the housing back side (25). The venting collection channel (14) is formed by a plurality of venting channel elements (13), which are connected to each other.