Nested Dual-Core Solenoid for Compact Shock Absorber Force Control
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Solution Overview
Problem
Existing solenoids for shock absorbers face challenges in providing sufficient driving force while maintaining a compact size, leading to increased machining costs and potential installation issues, and require additional fail valves that can impair ride quality when the solenoid fails.
Innovation Solution
A solenoid design with two movable iron cores, where the first movable iron core is tubular and slidably inserted into the second movable iron core, and a spring is interposed between the first movable iron core and the first fixed iron core, allowing for sufficient driving force without increasing the axial length, thus maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional solenoid design is used, then the structure is simple and machining cost is low, but the driving force is insufficient and the axial length must be increased to achieve sufficient force
Solution Approach 1:
The solenoid is divided into two separate coil assemblies: a first coil with a first movable iron core, and a second coil with a second movable iron core. Each coil assembly independently generates driving force, allowing the total driving force to be the sum of both assemblies while maintaining a compact axial length.
Solution Approach 2:
The first movable iron core is disposed inside the second movable iron core, creating a nested configuration. This allows both coil assemblies to occupy overlapping spatial volumes, effectively doubling the driving force generation capability within the same axial envelope, thus resolving the contradiction between sufficient driving force and compact size.
2Force
If the axial length of the solenoid is increased to provide sufficient driving force, then the driving force becomes adequate, but the machining cost increases and installation becomes difficult
Solution Approach 1:
By segmenting the solenoid into two independent coil assemblies that can be manufactured separately and then assembled, the patent avoids the need for a single large, complex solenoid structure. This segmentation allows each assembly to be manufactured using standard processes, reducing overall machining costs while achieving sufficient driving force through the combined output of both assemblies.
Solution Approach 2:
The nested configuration of the first movable iron core within the second movable iron core allows both coil assemblies to share the same axial space. This eliminates the need to increase axial length to achieve sufficient driving force, thereby avoiding increased machining costs and installation difficulties associated with longer components.
3Reliability
If a fail valve is added in parallel with the solenoid valve, then the damping force can be controlled at the time of failure, but the fail valve may open in normal times and back pressure cannot be controlled
Solution Approach 1:
The solenoid's two coil assemblies continuously generate driving force during normal operation, with the first coil assembly providing sufficient force to keep the fail valve closed without requiring a separate fail valve mechanism. The system serves its own fail-safe function through the redundant coil configuration, eliminating the need for an additional fail valve that would compromise normal operation.
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 solenoid achieves sufficient driving force at a lower cost without enlarging the solenoid, enabling efficient control of damping force in shock absorbers without increasing size, eliminating the need for additional fail valves and optimizing ride quality.
Implementation Method 1
a coil, a first fixed iron core disposed on an axial first-end side of the coil, a second fixed iron core disposed on an axial second-end side of the coil with a gap from the first fixed iron core
Implementation Method 2
a first movable iron core disposed between the first fixed iron core and the second fixed iron core and attracted to the first fixed iron core by passing a current through the coil, a second movable iron core disposed between the first fixed iron core and the second fixed iron core and attracted to the second fixed iron core by passing a current through the coil
Implementation Method 3
a spring interposed between the first movable iron core and the first fixed iron core and pressing the first movable iron core to the second fixed iron core side
Data Source
AI summary
A solenoid includes: a coil; a first fixed iron core disposed on an axial first-end side of the coil; a second fixed iron core disposed on an axial second-end side of the coil with a gap from the first fixed iron core; a tubular first movable iron core disposed between the first fixed iron core and the second fixed iron core: a second movable iron core having a tubular shape with a bottom, slidably inserted into the first movable iron core, disposed between the first fixed iron core and the second fixed iron core with a bottom portion facing the second fixed iron core; and a spring interposed between the first movable iron core and the first fixed iron core, and pressing the first movable iron core to the second fixed iron core side.