Two-Stage Solenoid Assembly for Extended Stroke Length
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current solenoid assemblies have limited stroke length, restricting their use in applications requiring longer linear actuation, which often necessitates the use of more complex and expensive linear actuators, such as linear motors, especially in space and weight-critical applications like aircraft door locks.
Innovation Solution
A solenoid assembly design featuring a static housing, a plunger, and an intermediate element, with a coil arrangement that provides two distinct magnetic actuation forces to extend the stroke length by translating the plunger and intermediate element together, allowing for increased movement without significant complexity or weight increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional solenoid assembly is used, then the structure remains simple and cost-effective, but the stroke length is limited
Solution Approach 1:
The solenoid assembly is segmented into two distinct coil arrangements (first and second coil assemblies) that operate independently to provide different magnetic actuation forces. This segmentation allows the system to achieve extended stroke length through staged actuation while maintaining the simplicity and cost-effectiveness of solenoid technology.
Solution Approach 2:
An intermediate element is introduced as a mediator between the plunger and the housing. This intermediate element responds to the first magnetic actuation force and transmits motion to the plunger, enabling extended stroke length without requiring a single complex actuation mechanism.
2Length of moving object
If a conventional solenoid assembly is used, then the structure remains compact and lightweight, but the stroke length is limited
Solution Approach 1:
The coil arrangement is divided into two separate coil assemblies that can be positioned at different locations within the housing. This segmentation allows for distributed weight and compact packaging while achieving extended stroke length through the combined action of both coils on the intermediate element and plunger.
3Length of moving object
If a conventional solenoid assembly is used, then the structure remains compact, but the stroke length is limited
Solution Approach 1:
The intermediate element is disposed within the housing and surrounds at least a portion of the plunger, creating a nested configuration. The first and second coil assemblies are also arranged within the housing in a space-efficient manner. This nesting allows extended stroke length to be achieved without proportionally increasing the overall assembly volume.
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 solenoid assembly achieves an extended stroke length while maintaining a compact and lightweight construction, enabling it to replace more complex actuators in various applications, including aircraft door locks, without requiring excessive electrical power or increased complexity.
Implementation Method 1
When current is passed through the coil of wire an electromagnetic force is exerted on the plunger to move the plunger within the coil of wire and thereby provide linear actuation
Data Source
AI summary
The present disclosure provides a solenoid assembly that includes a static housing, a plunger disposed within the housing and translatable along an actuation axis in response to a magnetic actuation force, an intermediate element disposed within the housing and surrounding at least a portion of the plunger that is also translatable along the actuation axis in response to a magnetic actuation force. A coil arrangement is disposed within the housing and provides a first and second magnetic actuation force in response to electrical excitation thereof. The coil arrangement is arranged such that the first magnetic actuation force is configured to translate the intermediate element and the plunger together with respect to the static housing, and the second magnetic actuation force is configured to translate the plunger with respect to the intermediate element. This can improve the stroke length of the solenoid assembly.