Solenoid Plunger Bore Alignment for Lower Valve Current
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Solution Overview
Problem
Current solenoid valves face issues with plunger misalignment due to draft angles in the bobbin's internal bore, leading to increased deformation of elastomer seals, higher current requirements, reduced pressure rating, and decreased valve efficiency and lifespan.
Innovation Solution
Incorporating undrafted, cylindrical bearing surfaces in the valve body bore to align the plunger, using bushings and over-molded polymer construction to maintain plunger alignment, and employing a conical section between bearing surfaces to enhance alignment precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a draft angle is used in the internal bore of the bobbin for moldability, then ease of manufacture is improved, but plunger alignment deteriorates
Solution Approach 1:
The bore is segmented into three distinct zones: an upper cylindrical bearing surface, a conical transition section, and a lower cylindrical bearing surface. This segmentation allows each zone to serve its specific function - the cylindrical sections provide alignment surfaces while the conical section facilitates moldability and plunger insertion, thereby resolving the contradiction between ease of manufacture and alignment precision.
Solution Approach 2:
The conical section acts as an intermediary element between the two cylindrical bearing surfaces. It serves as a transition zone that enables the mold to be opened and plunger to be inserted while the cylindrical sections maintain precise alignment. This intermediary conical section reconciles the conflicting requirements of manufacturability and alignment precision.
2Ease of operation
If the plunger is allowed to slide freely within the molded plastic bobbin, then ease of operation is improved, but alignment precision deteriorates
Solution Approach 1:
The bore is designed with different local qualities - the cylindrical sections provide precise alignment surfaces with tight tolerances for maintaining plunger alignment, while the conical section provides a transition zone that facilitates easy plunger insertion. This local differentiation allows the plunger to move freely in the operational zone while maintaining alignment precision in the bearing zones.
3Device complexity
If plunger misalignment occurs, then device complexity is reduced, but valve performance deteriorates
Solution Approach 1:
The bore is segmented into functional zones that inherently guide and align the plunger during insertion and operation. The upper and lower cylindrical bearing surfaces, separated by a conical section, create a self-aligning mechanism that ensures proper plunger positioning without requiring additional alignment devices or complex adjustment mechanisms, thus maintaining simple device structure while improving reliability.
Data Source
AI summary
A valve can include a valve body having a port section and a coil support section extending along a longitudinal axis, a plunger within a bore of the valve body and extending at least partially through the coil support section, and one or more cylindrical bore bearing surfaces in the bore to align the plunger within the bore.