Electromagnetic Valve Collision Surface Curvature
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Solution Overview
Problem
Conventional solenoid type electromagnetic fuel injection valves face challenges in maintaining high processing accuracy for collision structural parts under large collision loads, leading to stress concentration and wear, especially when surface treatments like electroplating result in uneven thickness, affecting the magnetic flux density and increasing wear and deformation.
Innovation Solution
The introduction of an R-shaped part and a flat part connected in a tangent manner on the collision structural parts helps distribute stress more evenly, reducing wear and deformation while maintaining productivity, by adjusting the plating thickness distribution to avoid stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projection with small width and height is formed on the facing surface of the fixed core or movable core to prevent stress concentration, then wear and deformation are reduced, but processing accuracy requirements increase significantly
Solution Approach 1:
The invention replaces the conventional projection structure with a curved surface structure having a specific radius of curvature. This curved surface distributes stress more evenly during valve closing collision, preventing stress concentration at sharp edges while avoiding the need for high-precision small feature processing. The curvature radius is specifically designed to balance stress distribution with manufacturability.
2Force
If the facing surfaces of fixed core and movable core are arranged close together to increase magnetic attraction force, then valve opening force is improved, but response property deteriorates due to increased squeezing force
Solution Approach 1:
The invention applies different surface characteristics to different regions of the facing surface. The central region has a curved surface with optimized radius to reduce squeezing force and improve response, while the peripheral region maintains appropriate geometry for magnetic circuit completion. This local differentiation allows simultaneous optimization of magnetic attraction and response properties.
3Strength
If electroplating is applied to the collision structural part to increase strength and wear resistance, then surface hardness is improved, but uneven thickness occurs due to uneven magnetic flux density
Solution Approach 1:
The curved surface structure is formed on the base material before applying the electroplating layer. This preliminary geometric modification ensures that during electroplating, the magnetic flux density distribution results in more uniform plating thickness across the collision surface, preventing the formation of protrusions that would cause stress concentration.
4Reliability
If the outer peripheral parts of collision structural parts are formed with high precision to prevent wear, then wear resistance is improved, but productivity decreases due to high processing accuracy requirements
Solution Approach 1:
The curved surface structure with optimized radius of curvature eliminates the need for high-precision processing of outer peripheral parts. The curvature naturally distributes stress away from the edges during valve operation, allowing standard machining processes to achieve sufficient wear resistance without requiring specialized high-precision operations, thereby maintaining productivity.
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 configuration effectively reduces stress on collision structural parts, suppressing wear and deformation, and improves the valve's response properties by balancing magnetic attraction and squeezing forces, even under high collision loads.
Implementation Method 1
attracting movable core formed as a movable iron core by a magnetic attraction force toward a fixed core formed as a fixed iron core
Implementation Method 2
surface treatment with high strength is applied to the collision structural part
Data Source
AI summary
It is important not to form the partial bump in the collision structural part, however the fixed core and the movable core are relatively inclined due to an accumulation of tolerances and therefore even if each collision structural part of the fixed core and the movable core in formed in a flat shape, the fixed core and the movable core are contacted with not the whole of the collision structural parts but a part of the collision structural parts at the moment of the collision. In a case in which the collision structural part is formed in a ring shape or an intermittent ring shape, the fixed core and the movable core are contacted with each other at outer peripheral parts. Thus, when the fixed core and the movable core are collided with each other, a high stress is applied to the outer peripheral parts contacted first. Accordingly, the shape of the outer peripheral parts of the collision structural parts is important, however since such a part, which is a tiny protruding shape, requires high processing accuracy, to reduce stress occurred during collision while keeping productivity is difficult. In the present invention, an R-shaped part and a flat part are provided in order from an outer peripheral side of a collision structural part. Further, the R-shaped part and the flat part are connected in a tangent manner.