Solenoid Valve Hook Coupling for Fast Assembly and Stable Actuation

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Solution Overview

Problem

Existing solenoid valves face challenges in efficient assembly and stability due to complex coupling mechanisms, which affect the speed and reliability of fluid flow control.

Innovation Solution

A solenoid valve design featuring a hooking type coupling system between the rod and mobile plunger, where the rod's coupling end hookingly couples to the mobile plunger's coupling element, allowing for axial movement and efficient assembly, while minimizing the removal of ferromagnetic material to maintain electromagnetic forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a complex coupling mechanism is used to connect the rod and mobile plunger, then the stability and reliability of connection is improved, but the assembly speed and manufacturing efficiency deteriorate

Engineering Contradiction:
Improveconnection stabilityVSAvoidassembly speed
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The coupling mechanism is divided into distinct functional elements: a coupling element with a recess on the mobile plunger and a coupling end with a protrusion on the rod. This segmentation allows for simple, quick assembly while maintaining reliable connection through the complementary geometric features.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The hooking coupling mechanism is designed to be self-aligning and self-locating through its geometric features (protrusion and recess). The components automatically guide themselves into the correct position during assembly, eliminating the need for complex alignment procedures or additional fastening operations.

Inventive Principle:
Principle #25Self-service

2Ease of manufacture

If ferromagnetic material is removed from the mobile plunger for coupling, then the ease of coupling is improved, but the electromagnetic forces are weakened

Engineering Contradiction:
Improvecoupling easeVSAvoidelectromagnetic force
Core Design Contradiction:
Ease of manufactureVSForce

Solution Approach 1:

The coupling features (protrusion and recess) are positioned on the lateral surface of the mobile plunger, utilizing the radial dimension rather than removing material from the axial face. This allows coupling to occur without interfering with the ferromagnetic material required for electromagnetic actuation.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The coupling elements are designed with specific geometric features (protrusion and recess) that provide sufficient mechanical engagement without requiring extensive material removal. The local geometry is optimized to achieve reliable coupling while preserving the bulk ferromagnetic material needed for electromagnetic forces.

Inventive Principle:
Principle #3Local quality

3Strength

If traditional coupling mechanisms are used, then the structural strength is maintained, but the assembly complexity increases

Engineering Contradiction:
Improvestructural strengthVSAvoidassembly complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The coupling mechanism merges the functions of connection, alignment, and positioning into a single integrated feature. The protrusion-c凹陷 combination simultaneously achieves all three functions, eliminating the need for separate alignment pins, adjustment mechanisms, or multiple fastening steps.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The hooking coupling design allows components to self-align and self-locate during assembly through their geometric features. The protrusion naturally guides into the recess, automatically establishing the correct relative position and orientation, which simplifies the assembly process while maintaining structural integrity.

Inventive Principle:
Principle #25Self-service

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

This design enhances assembly speed, maintains maximum electromagnetic efficiency, and ensures stability during dynamic operations by ensuring components move synchronously without delays.

Implementation Method 1

an electromagnetic coil positioned externally to the fixed member

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10955064B2Solenoid valve assembly and method of assembling the same
Publication Date: 2021.03.23 DPC HYDRAULICS SRL
  • US10955064B2 patent drawing
  • US10955064B2 patent drawing
  • US10955064B2 patent drawing

AI summary

A solenoid valve may have a fixed member having a tube portion. The valve may also have a mobile plunger positioned in the tube portion, the mobile plunger being axially movable between a first and a second position. The valve may also have a rod coupled to the mobile plunger and having a spool for control of fluid flow, the rod being axially movable in the tube portion. The valve may also have an electromagnetic coil positioned externally to the fixed member, where the rod has a coupling end and the mobile plunger has a coupling element where the coupling end hookingly couples to the coupling element.