Polymer Connecting Unit for Electromagnetic Actuator Tolerance
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Solution Overview
Problem
Electromagnetic actuator devices for camshaft actuation require multiple units, leading to large housing dimensions and increased costs due to separate housings and wiring, which are problematic in restricted engine block spaces and prone to thermal tolerance issues.
Innovation Solution
Mechanical connection of actuator units via a polymer-based bracket-like connecting unit with elasticity, allowing tolerance compensation and reduced housing size, along with a single plug connection for electrical activation, and integrated cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate actuator units are used for camshaft actuation, then the required actuating functions are achieved, but the housing dimensions and assembly complexity increase
Solution Approach 1:
The patent combines multiple actuator units into a single integrated housing structure. The housing contains multiple coil assemblies and armature tappets arranged in parallel, allowing multiple actuating functions to be performed within one unified structure rather than requiring separate housings for each actuator unit.
Solution Approach 2:
The single housing structure is designed to accommodate multiple actuator units that can perform different actuating functions simultaneously. The housing serves multiple purposes: structural support, electrical insulation, and containment for multiple electromagnetic actuating mechanisms, thereby achieving multi-functionality.
2Reliability
If multiple separate actuator units with individual housings are used, then actuating reliability is maintained, but assembly costs and wiring complexity increase
Solution Approach 1:
The patent merges multiple electrical connections into a single plug connection system. The housing contains integrated electrical terminals that can be connected via one plug assembly, eliminating the need for multiple separate wiring harnesses and reducing assembly complexity while maintaining reliable electrical connections for all actuator units.
Solution Approach 2:
The actuator units are segmented into modular components (coil assemblies, armature tappets) that can be independently manufactured and then assembled within the unified housing. This modular segmentation allows for standardized production and simplified assembly procedures.
3Area of stationary object
If multiple actuator units are installed in a common housing, then space is saved, but tolerance compensation for thermal expansion becomes difficult
Solution Approach 1:
The housing is designed with differentiated local properties: certain regions provide rigid structural support while other regions incorporate flexible or compliant elements that can accommodate thermal expansion. The mounting structures and connecting elements are specifically designed to allow for thermal movement without compromising the integrity of the entire assembly.
Solution Approach 2:
The housing and mounting structures are designed to change their physical parameters (such as dimensions or flexibility) in response to temperature variations. This allows the structure to adapt to thermal expansion and contraction of the actuator components, maintaining proper tolerances across different operating temperatures.
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
Enables compact, cost-effective installation with flexible tolerance compensation and simplified assembly, reducing structural and assembly costs while maintaining high reliability and switching dynamics.
Implementation Method 1
the respective actuator housings of the actuator units are movable relative to one another by the action of the connecting unit and corresponding to a predetermined bending property and/or elasticity of the connecting unit
Implementation Method 2
an armature unit which is configured in the manner of a tappet and which is able to be driven as a reaction to the energising of stationary coil means
Implementation Method 3
permanent magnets on the armature side cooperate in a repelling manner with the (energised) coil means
Data Source
AI summary
An electromagnetic actuator device with a plurality of actuator units (10, 12) having in each case an armature tappet which is movable relative to a stationary coil along an axial tappet direction when said coil is energised, said actuator units being received in respectively assigned actuator housings (11, 13) such that in an installed and/or assembled state of the electromagnetic actuator device one respective end portion (16) of the armature tappets may come into engagement in a controlled manner with an actuator partner which is able to be assigned thereto, wherein the plurality of actuator units is mechanically connected to a bracket-like and/or bridge-like connecting unit (14) made of polymer material such that the actuator housings are movable relative to one another by the action and in accordance with a predetermined bending property and/or elasticity of the connecting unit, in particular in a plane perpendicular to a tappet direction of the armature tappets which are further preferably guided in an axially parallel manner to one another.