Variable Valve Actuator Bracket Housing for Simpler Assembly
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Solution Overview
Problem
Existing electromagnetic actuating devices for variable valve drives have complex structures that complicate assembly and durability, particularly in the plastic/metal connection, and often require seals and inserts which can lead to tolerance issues and increased joining forces.
Innovation Solution
A simplified electromagnetic actuating unit design featuring a U-shaped bracket housing secured to a base plate, where the coil is mechanically decoupled from the housing and encapsulated with plastic overmolding, and the armature guide sleeve and pole core are formed as a one-piece component with a press fit and laser welding for reduced assembly forces and improved magnetic flux conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the coil is mechanically coupled to the housing, then the structure is more stable, but the durability is reduced due to problematic plastic/metal connections
Solution Approach 1:
The coil is extracted from the housing structure and mounted separately on the base plate. This separation eliminates the problematic plastic/metal connections between the coil and housing, while the coil remains mechanically stable through its independent mounting on the base plate using thermal contact rivets or crush ribs.
2Object-affected harmful factors
If the housing completely encloses the elements, then the protection from external influences is improved, but the assembly complexity increases
Solution Approach 1:
The housing is segmented into a bracket housing that is open on one side, allowing elements to be accessible from the outside. The base plate serves as a separate mounting surface for the coil, creating a modular assembly that is simpler to construct while still providing necessary protection through the bracket housing structure.
3Adaptability or versatility
If the armature guide sleeve and pole core are assembled as separate components, then the manufacturing flexibility is improved, but the tolerance chain increases and joining forces increase
Solution Approach 1:
The armature guide sleeve and pole core are merged into a single one-piece component. This eliminates the interface between the two parts, removing the tolerance chain and reducing the joining forces that would be required to assemble them separately, while the manufacturing process itself maintains flexibility.
4Strength
If thermal contact rivets are used to secure the coil, then the mechanical connection is strong, but the mechanical contact between soft iron circuit and coil cannot be avoided
Solution Approach 1:
The base plate serves as an intermediary between the coil and the housing structure. The coil is mounted on the base plate using thermal contact rivets or crush ribs, which provide strong mechanical connection while the base plate itself acts as the magnetic circuit element, eliminating direct mechanical contact between the coil and the soft iron 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 simplifies assembly, enhances durability by minimizing mechanical contact and tolerance chains, and maximizes power density by reducing magnetic resistance, while protecting the coil from external influences.
Implementation Method 1
An electromagnetic force generated by a coil acts on the armature, which means that an adjusting pin can be displaced
Implementation Method 2
The base plate can also form part of the magnetic circuit
Implementation Method 3
Crush ribs can be provided between the coil and the bracket housing and hold the coil on the base plate after deformation
Implementation Method 4
the armature guide sleeve and pole core are formed as a one-piece component with a press fit and laser welding
Data Source
AI summary
An electromagnetic actuating device (8) is for a variable valve drive, in particular electromagnetic switching valve lever systems. The electromagnetic actuating device comprises a base plate (3), a housing which is secured to the base plate (3) and a coil. The housing is designed as a bracket housing (12) and can form part of the magnetic circuit.