Reversing Linear Solenoid Spring Centering Dynamics
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Solution Overview
Problem
Reversing linear solenoids have low electrical efficiency, limited dynamics, and high armature speed at end stroke positions, leading to increased costs, power losses, and reduced service life, especially in applications requiring high switching frequencies and compact construction.
Innovation Solution
Incorporating a spring system that exerts a force towards the center stroke position in both end positions, with the spring force being smaller than the reluctance force in the static, non-energized case, allowing for higher forces, shorter adjustment times, and improved efficiency, and configuring the drive as monostable or bistable to achieve high dynamics and compact construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional reversing linear solenoids are used, then they can maintain state against returning force without control current, but electrical efficiency is low resulting in substantial costs and power losses
Solution Approach 1:
The patent applies dynamics by making the spring preforce adjustable rather than fixed. The spring preforce is adapted dynamically to match the specific application requirements, allowing optimization of the balance between spring force and reluctance force. This dynamic adaptation enables minimal control energy to be used while maintaining the desired holding force, thereby improving electrical efficiency and reducing power losses.
Solution Approach 2:
The patent changes the parameter of spring preforce from a fixed value to an adjustable parameter that can be optimized for different applications. By varying the spring preforce parameter, the system achieves optimal energy efficiency at different operating points, minimizing the control energy required while maintaining stable state holding capability.
2Speed
If conventional reversing linear solenoids are used, then they can provide bistable operation, but dynamics are small with long adjustment times and large dead times
Solution Approach 1:
The patent applies preliminary action by pre-tensioning the spring system before actuation occurs. The spring preforce is established in advance to create a ready-to-move condition, so that when control energy is applied, the armature can accelerate more quickly. This preliminary mechanical energy storage in the spring system reduces the time required for state transitions and minimizes dead time.
3Reliability
If conventional bistable reversing linear solenoids are used, then they can maintain position without control current, but armature speed is highest at end stroke positions causing high effort for damping and reduced service life
Solution Approach 1:
The patent applies preliminary anti-action by using the spring system to counteract the armature's momentum before it reaches the end stroke position. The spring preforce is configured to increase progressively as the armature approaches the end position, creating a cushioning effect that reduces impact speed. This preliminary opposing force prevents the harmful high-speed impact that would otherwise occur, reducing wear and extending service life.
4Force
If conventional reversing linear solenoids are used, then they can be designed for long stroke, but only small initial force is available and large tolerances are unavoidable
Solution Approach 1:
The patent applies the counterweight principle by using the spring system to provide a preforce that compensates for the reduced initial magnetic force in long-stroke applications. The spring preforce acts in the same direction as the magnetic force, effectively adding to the total initial force available. This mechanical counterbalance allows long-stroke designs to achieve sufficient initial force without requiring excessively tight manufacturing tolerances.
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 solution enables reversing linear solenoids to operate with higher electrical efficiency, reduced power losses, and increased switching frequencies while maintaining a compact design, with the spring system pre-accelerating the armature and storing kinetic energy for efficient operation.
Implementation Method 1
a spring system which exerts a force on the armature in both end stroke positions, the force being directed in the direction of movement toward the center stroke position
Implementation Method 2
the spring force in at least one end stroke position is smaller in magnitude than the total reluctance force acting on the armature in the static, non-energized case so that the armature can be kept stable in a permanent magnetic manner against the spring force
Data Source
AI summary
A reversing linear solenoid polarized in a permanent magnetic manner having a first and second end stroke position as well as at least one armature, wherein it has a spring system or is operated at such a spring system which exerts a force in the direction of the center stroke position on the armature or armatures in the end stroke position(s). The spring system and the reversing linear solenoid are coordinated with one another such that the armature or armatures are held in a permanent magnetic manner against the spring force in both end stroke positions. The spring system is configured such that the potential energy (elastically) stored by movement of the armature or armatures into its/their end stroke movements is of equal magnitude. If external restoring forces caused by the application are present, they must be taken into account in the design of the spring system.