Electromagnetic Piston Pump Layout Without Bushing Losses
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Solution Overview
Problem
Existing piston pumps face inefficiencies due to magnetic saturation of the piston, leading to limited pressure and volume per stroke, and the use of bushings induces eddy currents, reducing energy efficiency.
Innovation Solution
The design omits the bushing and reduces the distance between the coil windings and the piston, using a winding support to directly limit the piston chamber, allowing increased magnetic flux and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bushing is used to guide the piston in the piston chamber, then the piston is properly guided and sealed, but eddy currents are induced in the bushing which reduces energy efficiency
Solution Approach 1:
The invention removes the bushing component entirely from the system. Instead of using a bushing to guide the piston, the piston is directly guided by the piston chamber walls. This extraction of the problematic component eliminates the source of eddy current losses while maintaining the essential guidance function through the chamber geometry itself.
2Productivity
If the distance between the coil windings and the piston is reduced, then magnetic flux and pumping performance are enhanced, but the risk of magnetic saturation and mechanical contact increases
Solution Approach 1:
The invention optimizes the geometric parameters of the piston and coil assembly. By carefully designing the piston cross-sectional area, coil winding density, and axial spacing, the system achieves maximum magnetic flux density without saturating the piston material. The parameter optimization allows the piston to operate near its magnetic saturation point during the power stroke, maximizing force and delivery volume while preventing permanent saturation that would reduce performance.
3Force
If the piston cross-sectional area is increased to overcome magnetic saturation, then more magnetic flux is required which increases coil complexity and cost
Solution Approach 1:
Rather than simply increasing piston area, the invention optimizes multiple parameters simultaneously: piston cross-sectional area, magnetic path length through the piston, coil turns density, and coil current. This multi-parameter optimization achieves the required piston force with a moderately sized piston by maximizing the magnetic coupling efficiency, thereby avoiding the need for excessively complex or large coils.
4Ease of manufacture
If the winding support directly limits the piston chamber, then manufacturing costs are reduced and energy loss is minimized, but the precision of piston chamber delimitation must be maintained
Solution Approach 1:
The invention merges the functions of the winding support and the piston chamber wall into a single integrated component. The winding support structure simultaneously serves as the radial boundary for the piston chamber, eliminating the need for a separate bushing or sleeve. This integration reduces part count and manufacturing cost while the precise machining of the winding support's inner surface ensures accurate piston chamber delimitation.
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 enhances delivery volume and pressure while minimizing energy loss, achieving higher efficiency and cost-effectiveness.
Implementation Method 1
By providing an electric current through the coil, a magnetic field can be generated, that forces the piston against restoring force of the elastic element
Implementation Method 2
Shutting the magnetic field of causes the piston to be pushed back into its initial position by the elastic element
Implementation Method 3
the first check valve may be configured to block a fluid flow from the outlet channel towards the inlet channel via the piston channel
Data Source
AI summary
A piston pump configured to pump a fluid and including an inlet channel, an outlet channel, a piston, an armature, an elastic element, a first check valve, a piston chamber, a longitudinal axis, a winding support, and a coil. The piston is movably supported parallel to the longitudinal axis in a piston chamber and has a first face with a piston channel inlet, a second face with a piston channel outlet, and a piston channel connecting the piston channel inlet and the piston channel outlet. The piston is biased in a first axial direction by the elastic element. The first check valve is arranged in the piston channel. The coil has at least one winding arranged on the winding support. The inlet channel is configured to communicate with the piston channel inlet and the outlet channel is configured to communicate with piston channel outlet.