Proportional Solenoid Conical Air Gap Hysteresis
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Solution Overview
Problem
Solenoid-based systems face challenges in maximizing efficiency, linearity, and proportionality while minimizing hysteresis effects, as existing designs often prioritize one characteristic over others, leading to suboptimal performance in fluid control applications.
Innovation Solution
A two-way proportional solenoid apparatus with a ferromagnetic housing and pole piece design that includes a non-magnetic material-filled recess, a stiffer combination of guide and valve springs, and a conical air gap to enhance magnetic flux and axial force, reducing hysteresis and improving fluid flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a solenoid is designed to maximize efficiency, then force per unit of supplied energy is improved, but linearity and proportionality deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the magnetic circuit geometry (conical air gap instead of parallel gap) and spring characteristics (stiffer spring combination) to alter the force-current relationship. This transforms the traditionally nonlinear solenoid operation into a more linear proportional response, allowing the system to achieve both high efficiency and improved linearity simultaneously
2Manufacturing precision
If a solenoid is designed to maximize linearity, then movement proportionality is improved, but hysteresis effects worsen
Solution Approach 1:
The patent utilizes curvature by implementing a conical air gap between the armature and pole piece, replacing the traditional parallel gap. This conical geometry creates a more uniform magnetic flux distribution that reduces magnetic saturation effects and minimizes hysteresis, thereby improving both linearity and reducing harmful hysteresis effects
3Manufacturing precision
If spring stiffness is increased to improve linearity, then movement control is improved, but axial force deteriorates
Solution Approach 1:
The conical air gap geometry enhances magnetic flux concentration in the axial direction, compensating for the increased spring stiffness. This curvature-based design ensures that the magnetic pulling force remains sufficient even with stiffer springs, allowing the system to achieve improved linearity without sacrificing axial force
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 apparatus achieves more linear operation with reduced hysteresis and increased axial force for a given current, enabling improved fluid flow control and efficiency by optimizing magnetic flux distribution and spring stiffness, allowing for proportional fluid flow control.
Implementation Method 1
a coil assembly comprising a coil wound around a bobbin. Pins protrude through openings in the end of the housing. The coil is electrically connected to the pins
Implementation Method 2
A two-way proportional solenoid apparatus with a ferromagnetic housing and pole piece design that includes a non-magnetic material-filled recess
Implementation Method 3
The housing is ferromagnetic and is substantially cylindrical in construction. A ferromagnetic core piece is disposed within the bobbin, and abuts a ferromagnetic pole piece
Implementation Method 4
a non-magnetic material-filled recess, a stiffer combination of guide and valve springs, and a conical air gap to enhance magnetic flux and axial force
Implementation Method 5
The armature assembly includes a guide spring and a valve spring. The guide spring is attached to the pole piece and to the armature
Implementation Method 6
a conical air gap to enhance magnetic flux and axial force, reducing hysteresis and improving fluid flow control
Data Source
Figure 1~3
Figure 4~5
Figure 6~10
AI summary
An apparatus may include a ferromagnetic housing defining a housing cavity, an electrically-conductive coil disposed in the housing cavity and defining a coil cavity, a ferromagnetic core piece disposed in the coil cavity, a ferromagnetic pole piece comprising a first face in contact with the core piece and a projection extending from a second face of the pole piece opposite the first face, a flexible element defining an opening, where the projection is disposed within the opening and the flexible element is disposed between a portion of the projection and the first face of the pole piece, and a ferromagnetic armature coupled to the flexible element, where the flexible element is disposed between at least a portion of the armature and the first face of the pole piece.