Valve Coil Assembly With Radial Preload for Easier Mounting
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Solution Overview
Problem
Existing coil assemblies require high joining forces and strict component positioning, making them costly and challenging to produce.
Innovation Solution
A coil assembly design featuring a flux conducting device with intermeshed ferromagnetic pole and counter-pole rings that are elastically preloaded in a radial direction, allowing for optimal magnetic field conduction without the need for precise alignment and high joining forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional coil assemblies are designed with rigid component connections, then structural stability is improved, but manufacturing complexity and cost increase due to high joining forces and strict positioning requirements
Solution Approach 1:
The patent applies the dynamics principle by replacing rigid fixed connections with elastic spring elements that provide dynamic, flexible connections between components. The spring elements can deform and adapt to positioning tolerances while maintaining stable mechanical coupling, thus achieving structural stability without requiring strict positioning or high joining forces during assembly.
Solution Approach 2:
The patent changes the mechanical parameters of the connection system by introducing elastic spring elements with specific stiffness characteristics. These springs provide sufficient holding force for structural stability while requiring minimal assembly force, thereby reducing manufacturing complexity and cost.
2Manufacturing precision
If traditional coil assemblies use fixed rigid connections, then component positioning precision is maintained, but assembly difficulty increases due to high joining forces and strict positioning requirements
Solution Approach 1:
The spring elements provide dynamic positioning capability, allowing components to be easily assembled without strict positioning requirements. The elastic deformation of the springs compensates for manufacturing tolerances while maintaining precise relative positioning during operation, thus improving ease of manufacture without sacrificing positioning precision.
Solution Approach 2:
The spring elements perform self-alignment and self-adjustment during assembly, automatically compensating for positioning deviations. This self-service mechanism eliminates the need for precise manual positioning or complex alignment procedures, significantly reducing assembly difficulty.
3Reliability
If elastic preloading is applied in radial direction, then magnetic field conduction is optimized through tight lateral clamping, but component design complexity increases
Solution Approach 1:
The patent segments the flux conducting device into multiple independent components (pole ring, counter-pole ring, spring elements) that can be manufactured separately using standard machining processes. This segmentation allows each component to have a simple, manufacturable design while the assembled system achieves optimized magnetic field conduction through the elastic preloading mechanism.
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 design enables efficient magnetic field conduction while simplifying the mounting process, reducing production costs and complexity by allowing components to be slid axially and clamped radially, thus optimizing both conduction and assembly characteristics.
Implementation Method 1
having a one-piece ferromagnetic pole ring of a ferromagnetic material... and a one-piece ferromagnetic counter-pole ring of a ferromagnetic material... for conducting magnetic field lines of a magnetic field
Implementation Method 2
coil arrangement comprising at least one electrically energizable coil... for providing a magnetic field
Implementation Method 3
elastically preloaded in a radial direction, tightly clamp the same components laterally to one another... elastically preloaded, are clamped laterally touchingly on the counter-ring base plate
Data Source
AI summary
A coil assembly, e.g., for use a valve, is disclosed. The coil assembly includes a coil arrangement including at least one electrically energizable coil, a coil ring carrier receiving the coil arrangement, and a flux conducting device for conducting magnetic field lines of a magnetic field provided via the coil arrangement. The flux conducting device includes a one-piece ferromagnetic pole ring that includes a ring base plate and a plurality of pole ring outer teeth arranged on an outer edge of the ring base plate and angularly bent over on fold-over outer edge regions of the ring base plate. The flux conducting device further includes a one-piece ferromagnetic counter-pole ring that includes a counter-ring base plate and a plurality of counter-pole ring outer teeth arranged on a counter-outer edge of the counter-ring base plate and angularly bent over on counter-fold-over outer edge regions of the counter-ring base plate.