Valve Actuator With Bifurcating Magnetic Core
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Solution Overview
Problem
Existing valve actuators for fluid working machines, particularly in synthetically commutated hydraulic systems, face challenges in achieving fast, accurate, and reproducible actuation with high holding forces while maintaining low power consumption, often requiring complex and heavy designs with two coils, which increase size, weight, and cost.
Innovation Solution
A valve actuator design featuring a magnetic core with a bifurcating branch, a variable magnetic field generating device, a permanent magnetic field generating device, and a movable magnetic component, where the bifurcating branch defines two regions allowing for controlled magnetic flux distribution, enabling rapid acceleration and precise actuation by canceling the permanent magnetic flux and generating additional forces through the variable magnetic field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two coils are used in the valve actuator to achieve fast and accurate actuation with high holding forces, then the actuation performance is improved, but the device complexity, size, and weight increase
Solution Approach 1:
The patent combines the functions of two separate coils into a single coil system. The first and second coils in the prior art are merged into one coil that generates a variable magnetic field, reducing the number of components while maintaining the ability to achieve fast actuation and high holding forces through controlled magnetic flux distribution.
Solution Approach 2:
The single coil in the invention serves multiple functions: it generates the variable magnetic field for both actuation (overcoming the holding force) and control (adjusting flux distribution). Additionally, the magnetic core with bifurcating branch structure enables the system to perform both the holding function and the actuation function using a unified component architecture.
2Force
If two coils are used to generate sufficient magnetic force for rapid actuation, then the actuation force is improved, but the power consumption increases
Solution Approach 1:
The permanent magnet in the invention performs preliminary action by providing a continuous holding force without requiring power consumption. This pre-established magnetic field eliminates the need for continuous energization of coils to maintain the holding position, significantly reducing power consumption while maintaining high holding forces.
Solution Approach 2:
The coil is energized periodically and temporarily only when actuation is required, rather than continuously. The variable magnetic field generating device activates the coil in a controlled manner to overcome the permanent magnet's holding force during the brief actuation period, then deactivates it, creating a periodic action pattern that reduces overall energy consumption.
3Speed
If the magnetic flux is increased to improve actuation speed, then the response time is reduced, but the energy loss increases
Solution Approach 1:
The magnetic core features a bifurcating branch structure that creates distinct first and second regions with different magnetic flux characteristics. This local differentiation allows the system to concentrate magnetic flux where needed for rapid actuation while maintaining efficient flux distribution elsewhere, optimizing the balance between actuation speed and energy efficiency in different parts of the magnetic circuit.
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 achieves faster and more precise actuation with reduced energy consumption, as the variable magnetic field builds up force gradually while the permanent magnetic field holds the component in place, allowing for efficient operation and reduced complexity.
Implementation Method 1
at least one permanent magnetic field generating device
Implementation Method 2
The flux produced by the magnet is sufficient to hold the valve member in contact with pole faces
Implementation Method 3
at least one variable magnetic field generating device
Implementation Method 4
The flux produced by the magnet is enhanced when a first coil is energized to lift the valve member
Implementation Method 5
at least one magnetic flux limiting means, whose magnetic flux limit can at least be reached
Data Source
AI summary
The invention relates to a valve actuator (2), comprising a magnetic core (6) with an interspace (8) and at least one bifurcating branch (7), at least one variable magnetic field generating device (16), at least one permanent magnetic field generating device (13) and at least one movable magnetic component (12), wherein the bifurcating branch (7) defines a first region (4) and a second region (5) of said magnetic core (6). Said movable magnetic component (12) is movably arranged within said interspace (8) of said magnetic core (6) in such a way that a first gap (19) is formed between a first surface (23) of said movable magnetic component (12) and a first surface (22) of said interspace (8) of said magnetic core (6), a second gap (20) is formed between a second surface (24) of said movable magnetic component (12) and a second surface (25) of said interspace (8) of said magnetic core (6), and a third gap (21) is formed between a third surface (27) of said movable magnetic component (12) and a third surface (26) of said bifurcating branch (7) of said magnetic core (6). At least one of said variable magnetic field generating devices (48, 49) is associated with said first region (4) of said magnetic core (6) and at least one of said permanent magnetic field generating devices (13) is associated with said second region (5) of said magnetic core (6). Said valve actuator (2) is designed and arranged in a way that a magnetic flux, generated by at least one at least one of said variable magnetic field generating devices (16) is able to exert a force on said at least one movable magnetic component (12) and is able to cancel the magnetic flux (48, 49), generated by at least one of said permanent magnetic field generating devices (13). At least one magnetic flux limiting means (7, 12) is provided, whose magnetic flux limit can be reached or exceeded.