Solenoid Yoke Protrusions for Precise Coil Assembly
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Solution Overview
Problem
The radial gap between the yoke and the coil in solenoids can cause eccentricity issues during assembly, leading to deteriorated assemblability and potential performance problems.
Innovation Solution
The solenoid design incorporates protrusions on the inner or outer surfaces of the coil and yoke to reduce the size of the radial gap, preventing eccentricity and improving assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a radial gap is formed between the yoke and the coil portion, then the coil can be easily assembled and positioned, but the gap causes eccentricity issues and deteriorates assembly precision
Solution Approach 1:
Protrusions are formed on the yoke or coil portion before assembly to pre-establish the correct radial positioning. These protrusions guide the coil into proper alignment with the yoke, preventing eccentricity during the assembly process while maintaining ease of assembly through the guiding function.
Solution Approach 2:
The protrusions act as intermediary elements between the yoke and the coil portion. They mediate the assembly process by providing a physical guide that ensures precise radial alignment, allowing the components to be assembled easily while achieving high assembly precision through the mediating protrusion structures.
2Manufacturing precision
If the radial gap between the yoke and coil is reduced to improve assembly precision, then assembly accuracy improves, but the complexity of the structure increases due to protrusions
Solution Approach 1:
Instead of reducing the radial gap uniformly throughout the entire circumference, protrusions are strategically placed at specific locations where they are most effective for guiding alignment. This local approach maintains simplicity in the majority of the structure while providing precision enhancement only where needed, minimizing overall structural complexity.
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 protrusions effectively suppress the deterioration of assemblability by guiding the coil's insertion and reducing the radial gap, enhancing the solenoid's assembly accuracy and performance.
Implementation Method 1
a coil portion having a coil that generates a magnetic flux when energized
Implementation Method 2
a magnetic attraction core arranged in the axial direction to face a distal end of the plunger and configured to attract magnetically the plunger by a magnetic force generated by the coil
Data Source
AI summary
A solenoid includes a coil portion and a yoke having a side surface portion along an axial direction so as to accommodate the coil portion. A gap in a radial direction that communicates a radial outside of a first magnetic flux transfer portion with an outside of the solenoid is formed between an inner surface of the side surface portion and an outer surface of the coil portion, and a protrusion is formed on at least one of an inner surface and an outer surface and protrudes in the radial direction to reduce a size of at least a part of the gap.