Patent Application
20100097165
The present invention relates broadly to electromagnetic control devices, and more particularly, pertains to a solenoid assembly having a cushioning arrangement for maintaining the integrity of a plunger moving within the solenoid.
As is well known, a solenoid assembly consists essentially of a coil of wire or winding that is wrapped around a hollow bobbin. An enclosure or frame made of a magnetically conductive material normally contains the coil. An actuator or plunger moves back and forth within a passageway formed in the bobbin. Application of electrical power to the coil will move the plunger between an energized, latched position and a de-energized, unlatched position. A return spring is provided to assist movement of the plunger back to the unlatched position. Typically, the plunger is designed with some sort of feature which allows users to connect whatever structure they would need to actuate with it. At one end of the solenoid assembly in the passageway of the bobbin and rigidly attached to the frame is a slug of magnetic material known as a backstop. The backstop establishes the maximum pulling distance the plunger can achieve when the coil is energized by electrical power. The coil is normally wound to parameters that will dictate the amount of electromagnetic forces placed upon the plunger based upon a desired application.
When a solenoid coil is momentarily energized, the electromagnetic energy causes the plunger to move towards the backstop into the latched position compressing the return spring. As the plunger approaches the backstop, its level of force generally increases. When the plunger impacts and bottoms out on the backstop, the maximum amount of pulling power is achieved. In a magnetic latching solenoid, power to the coil is removed and a set of permanent magnets in the frame is used to hold the plunger in its latched position. When it is desired to move the plunger to an unlatched position, the solenoid coil is momentarily energized to overcome the force of the permanent magnets after which release of the compressed spring force completes the return movement of the plunger.
In certain high wattage applications when the solenoid is moved to the latched position, the plunger imposes a large impact loading upon the rigidly connected backstop. Upon repeated use, this impact loading deforms the plunger such that movement of the plunger is impaired leading to the failure in the solenoid performance.
Accordingly, it is desirable to provide a solenoid assembly which avoids failures due to destructive impact loading between the plunger and backstop. More specifically, it is desirable to provide the solenoid assembly with a modified connection between the backstop and the frame, and position a shock absorbing element between the backstop and the frame to prevent damage to the plunger over repeated cycles of use and extend the service life of the solenoid assembly.
The present invention relates to a solenoid assembly including a solenoid having a coil provided with a passageway and a plunger movable within the passageway upon application of the electrical power to the coil. A frame holds the solenoid and includes a backstop extending into the coil passageway. The backstop is selectively engaged by the plunger such that the backstop and plunger are subject to an impact therebetween. A resilient dampening element is positioned between the frame and the backstop for cushioning the impact between the backstop and the plunger.
In the preferred embodiment, the backstop is movably mounted relative to the frame. The resilient dampening element is an O-ring encircling the plunger. A solenoid assembly includes holding elements for maintaining a prescribed position of the plunger. The holding elements include a pair of permanent magnets surrounding a portion of the coil and positioned adjacent one end of the coil in the frame. The holding elements further include a spring positioned between the frame and the plunger.
In another aspect of the invention, a solenoid assembly includes a solenoid having a coil provided with a passageway, and a plunger movable within the passageway upon application of electrical power to the coil between a latched position and an unlatched position. A magnetic latching arrangement surrounds the plunger and is positioned adjacent the coil for holding the plunger in the latched position. A frame holds the coil and the magnetic latching arrangement and includes a separate backstop movably mounted in the frame and extending into the coil passageway. The backstop is selectively engaged by the plunger such that the backstop and plunger are subject to an impact therebetween. A spring surrounds the plunger for normally biasing the plunger to the unlatched position. A resilient, shock absorbing ring encircles the backstop and is positioned between the backstop and the frame for preventing damage to the plunger upon impacting the backstop.
The magnetic latching arrangement includes a pair of permanent magnets encircling the plunger and a portion of the coil. The plunger has a main body, an outer end projecting from the frame and an inner end engageable with the backstop. The frame includes a pair of sidewalls connected by a back wall having a recess formed therein. The frame further includes an end plate connecting the sidewalls and spaced from the back wall. The backstop has a first cylindrical portion positioned in the passageway of the coil, and a second cylindrical portion mounted in the recess of the back wall. The inner end of the plunger has an circumferential shoulder engageable with a circular inner end of the backstop. The backstop is formed with an aperture which receives a portion of the inner end of the plunger. The backstop is restrained from moving inwardly in the passageway by a ring retained on the second cylindrical portion of the plunger and engaged against the frame. The shock absorbing ring is located between the first and second cylindrical portions of the backstop. The impact between the plunger and the backstop causes the ring to compress and enable movement of the backstop. A washer surrounds the main body of the plunger. The spring has one end positioned against the washer and another end engaged against the frame.
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
Referring now to the drawings,
The solenoid 12 includes a bobbin-based electromagnetic coil 20 with a stovepipe portion 22 which together form a cylindrical interior passageway 24. The coil 20 is surrounded with a protective encapsulation 26 (
The plunger 16 is slidably moved back and forth in the passageway 24 as power to the coil 20 is applied in a sense that produce fields which respectively aid and oppose the field of the magnets 14. The plunger 16 is substantially cylindrical and includes a main body 32, an outer end 34 having a reduced diameter relative to the main body 32 and an inner end 36 having a generally conical end 38 extending from a circumferential shoulder 40. Plunger 16 has a circumferential notch 42 that holds a retaining ring 44 against one side of a non-magnetic washer 46 which encircles the main body 32.
The frame 18 is constructed from a generally U-shaped rigid member, and includes a pair of spaced sidewalls 48, 50 connected by a back wall 52 having a recess 54. The sidewalls 48, 50 have lengths which extend beyond the combined lengths of the magnets 14 and the coil 20. At least one sidewall 48 is formed with a pair of holes 56 to facilitate mounting of the frame 18. As seen best in
The back wall 52 of the frame includes a separate plug-like backstop 64 which is selectively engaged by the shoulder 40 of plunger 16 upon energization of coil 20. The backstop 52 has a first cylindrical portion 66 which is received in the coil passageway 24 adjacent the back wall 52. The backstop 52 has a second cylindrical portion 68 having a smaller diameter than the diameter of first cylindrical portion 66. The backstop 52 is secured against any inward movement of the coil passageway 24 by a retaining ring 70. The ring 70 is engaged in a circumferential notch 72 formed in the second cylindrical portion 68, and normally abuts an external surface of back wall 52. The backstop 64 is formed with an aperture 74 to release air from the coil passageway 24 during plunger movement, and aid in preventing corrosion of the plunger 16. The aperture 74 opens into a frustoconical portion 76 which is designed to accommodate the conical inner end 38 of plunger 16. The frustoconical portion 76 terminates in a circular inner end 78 of the backstop 64 which is selectively impacted upon by the moving shoulder 40 of the plunger 16.
A resilient dampening element in the preferred form of a compressible, shock absorbing O-ring 80 encircles the second cylindrical portion 68 of the backstop 64. The O-ring 80 is positioned in passageway 24 between the backstop 64 and the back wall 52 of the frame 18 inwardly of the coil 20. It is a function of the O-ring 80 to act as a resilient bumper and cushion the impact between the plunger 16 and the backstop 64 during repeated solenoid operation so as to prevent damage to the plunger 16 particularly along its annular shoulder 40.
In use, the assembly 10 is brought to a latched position shown in
In a high wattage application, the plunger 16 moves quickly and forcefully. The impact of loading between the plunger 16 and the backstop 64 can be severe enough to deform the shoulder 40 of the plunger 16 over repeated cycles of use. However, the compression of the shock absorbing O-ring 80 positioned around the movably mounted backstop 64 adjacent the frame back wall 52 enables a temporary small outward deflection of the backstop 64 relative to the back wall 52 which prevents damage to the impact surface of the plunger 16.
Once full impact has occurred between the plunger 16 and the backstop 64, the resiliency of the O-ring 80 will return the backstop 64 to its original position. The plunger 16 is held in its latched position by the force of the permanent magnets 14 alone as power to the coil 20 is removed. The assembly 10 is brought to an unlatched position shown in
It should be appreciated that the present invention thus provides an arrangement particularly useful in protecting the integrity of a plunger continuously subjecting high impact forces upon a backstop in a solenoid assembly. The arrangement relies upon the backstop being movably mounted relative to the frame and provided with an encircling shock absorbing O-ring adjacent the frame to dampen the impact between the plunger and the backstop, and thereby extend the lifetime of the solenoid assembly.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only and should not be deemed limitative on the scope of the invention set forth with the following claims.
