Solenoid Actuator Buffer Structure With Single-Diameter Shaft
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Solution Overview
Problem
Conventional electromagnetic solenoids have complex shaft machining, high costs, and complicated assembly processes due to stepped shaft designs and the need for precise impact absorption mechanisms.
Innovation Solution
An electromagnetic actuator with a single outer diameter shaft, a buffer unit, and a compression-type coil spring biasing member, which simplifies the structure, reduces costs, and streamlines assembly by using a forged mover and crimped restricting parts to secure the buffer unit components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stepped shaft design is used to accommodate the spring and buffer material, then the impact absorption function is improved, but the machining complexity and manufacturing cost increase
Solution Approach 1:
The shaft is divided into two functional parts: a simple cylindrical main body for guidance and a separate head portion press-fitted into the mover for receiving the spring and buffer material. This segmentation allows the main body to have uniform diameter (reducing machining complexity) while the head portion provides the necessary functional features (improving impact absorption).
Solution Approach 2:
The functional features for receiving the spring and buffer material are extracted from the shaft and transferred to a separate head portion that is press-fitted into the mover. This extraction simplifies the shaft's machining requirements while maintaining the impact absorption function through the dedicated head portion.
2Reliability
If a stepped shaft with integrated spring receiving structure is used, then the retaining structure is improved, but the assembly work of spring and buffer material becomes complicated
Solution Approach 1:
The shaft is segmented into a main body and a separate head portion that is press-fitted into the mover. The head portion contains the recess for receiving the spring and buffer material, separating the retention function from the guidance function. This allows the spring and buffer material to be assembled into the head portion independently, simplifying the overall assembly process.
3Ease of manufacture
If a single outer diameter shaft is used, then the machining complexity and cost are reduced, but the structure for receiving spring and buffer material becomes more difficult
Solution Approach 1:
The complex structure for receiving the spring and buffer material is extracted from the shaft and placed in a separate head portion that is press-fitted into the mover. This allows the shaft to maintain a simple uniform diameter (reducing machining complexity) while the head portion provides the necessary functional features (maintaining the retention structure).
Solution Approach 2:
The head portion acts as an intermediary component between the simple cylindrical shaft and the mover. It receives the shaft through press-fit connection and provides the recess for accommodating the spring and buffer material, thus mediating between the simplified shaft design and the functional requirements.
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 achieves simplification of structure and cost reduction, while effectively absorbing impact and positioning the mover at rest positions with high accuracy, enhancing wear resistance and mechanical strength.
Implementation Method 1
a biasing member which biases the rod toward the stator
Implementation Method 2
the biasing member may be a compression-type coil spring
Implementation Method 3
a buffer member which is interposed between the rod and the shaft... absorbing impact when the mover returns to the rest position
Implementation Method 4
an electromagnetic actuator using an electromagnetic force of a solenoid as a driving force... the mover moves in a predetermined axial direction to move to an actuation position due to energization of the coil
Data Source
AI summary
An electromagnetic actuator includes a stator, a coil for excitation, a mover, a shaft of a single outer diameter, and a buffer unit. The mover moves in a predetermined axis direction to move to an actuation position due to energization of the coil and return to a rest position due to non-energization of the coil. The shaft is fixed to the mover and exerts a driving force to outside. The buffer unit is held at the mover and positions the mover at the rest position while absorbing impact when the mover returns to the rest position. The buffer unit includes: a rod abutting against the stator at the rest position; a biasing member biasing the rod toward the stator; and a buffer member interposed between the rod and the shaft. The mover includes a fitting hole into which the shaft is fitted and a receiving part receiving the biasing member.