Pre-Assembled Electromagnet Structure for Simpler Valve Actuation Assembly
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Solution Overview
Problem
Existing electromagnets, particularly those used for actuating valves, have a large number of individual components that require complex and time-consuming assembly processes.
Innovation Solution
The electromagnet is designed with a pre-assembly unit comprising a guide element and a coil, which is inserted into an axially extending annular protrusion of a core, reducing the number of components and simplifying assembly by integrating the coil carrier, armature, and other components into a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional electromagnets use multiple individual components (housing, coil carrier, guide pot, return elements), then the electromagnet can be assembled with standardized parts, but the number of assembly steps and manufacturing complexity increases significantly
Solution Approach 1:
The patent combines the housing, guide element, and coil carrier into a single integrated housing structure. The housing directly forms the guide element for armature movement and provides mounting structures for the coil, eliminating the need for separate guide pots and coil carriers. This merging reduces the component count from multiple individual parts to a unified structure, simplifying assembly while maintaining functional requirements.
2Productivity
If the electromagnet uses a separate housing and multiple mounting components, then each component can be manufactured independently, but the overall assembly time and labor requirements increase
Solution Approach 1:
By integrating the guide element and coil mounting structures directly into the housing, the patent eliminates multiple assembly steps for positioning and securing separate components. The housing is designed with integrated features that simultaneously provide guidance, support, and electrical isolation, allowing these functions to be achieved in a single manufacturing step rather than through multiple assembly operations.
3Ease of repair
If the electromagnet uses multiple separate components, then individual components can be replaced or repaired independently, but the overall device complexity and assembly requirements increase
Solution Approach 1:
While the housing is integrated, the patent maintains segmentation in other critical components such as the armature, coil assembly, and return elements. These segmented components can still be independently replaced or repaired, preserving maintenance flexibility. The integrated housing provides a simplified structure that reduces overall assembly complexity while the modular critical components retain their replaceability for ease of repair.
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 design significantly reduces manufacturing and assembly efforts by eliminating the need for a separate housing and allowing for a more straightforward, cost-effective assembly process.
Implementation Method 1
The magnetic attraction force generated by a current flow in a coil
Implementation Method 2
a magnetic circuit is closed by the core, the armature, a yoke, and any magnetic return elements present
Data Source
AI summary
An electromagnet includes a pre-assembly unit having a guide element and a coil, an armature which is arranged translationally displaceable in the guide element, and a core having an axially extending annular protrusion into which the pre-assembly unit is inserted.