U.S. patent number 3,683,239 [Application Number 05/153,939] was granted by the patent office on 1972-08-08 for self-latching solenoid actuator.
This patent grant is currently assigned to Negev Products Corp., Northridge, CA. Invention is credited to Oded E. Sturman.
United States Patent |
3,683,239 |
|
August 8, 1972 |
SELF-LATCHING SOLENOID ACTUATOR
Abstract
A self-latching solenoid actuator having a low power consumption
and an internal switching arrangement whereby latching and
unlatching may be accomplished by such means as a simple
single-pole, double-throw remote switch. The solenoid has a
permanent magnet in the magnetic circuit thereof so that an
actuating current in a first direction will actuate the solenoid
and charge the permanent magnet, and a smaller current in the
opposite direction will de-magnetize the permanent magnet and allow
a return spring to force the plunger to the fully extended
position. A single-pole, double-throw switch electrically coupled
to the solenoid coil is disposed adjacent the magnetic circuit and
mechanically coupled to the solenoid plunger. The switch is coupled
in the circuit so as to be operative to turn off the actuating
current and the unlatching current as the plunger approaches the
latched and unlatched positions respectively, and to re-connect the
solenoid coil in preparation for the next operating signal.
Inventors: |
Oded E. Sturman (Northridge,
CA) |
Assignee: |
Negev Products Corp., Northridge,
CA (N/A)
|
Family
ID: |
22549336 |
Appl.
No.: |
05/153,939 |
Filed: |
June 17, 1971 |
Current U.S.
Class: |
361/194; 335/170;
335/234; 361/208; 335/179; 361/147 |
Current CPC
Class: |
H01H
50/20 (20130101); H01H 51/2209 (20130101); H01H
47/226 (20130101) |
Current International
Class: |
H01H
50/16 (20060101); H01H 47/22 (20060101); H01H
50/20 (20060101); H01H 51/22 (20060101); H01h
009/20 (); H01h 047/04 () |
Field of
Search: |
;317/150,154,157
;335/170,179 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: L. T. Hix
Attorney, Agent or Firm: Spensley, Horn and Lubtiz
Claims
1. A solenoid actuator having a stationary member and a moving
member adapted for motion between first and second orientations
with respect to said stationary member, a solenoid coil having
first and second leads, a permanent magnet, and a switch, said
stationary member and said moving member forming a magnetic circuit
with said permanent magnet in said circuit, said solenoid coil
being disposed with respect to said magnetic circuit so as to cause
a magnetizing force in said circuit in response to a current
therethrough, said stationary member and said moving member being
adapted to magnetically urge said moving member toward said first
orientation with respect to said stationary member in response to
the establishment of a magnetic field in said magnetic circuit,
said switch being electrically coupled to said first solenoid coil
lead and adapted to switch electrical coupling with said first
solenoid coil lead between first and second actuator leads in
response to motion between said
2. The solenoid actuator of claim 1 wherein said switch has
mechanical hysteresis so that said switch will not switch
electrical coupling with said first solenoid lead between said
first and second actuator leads until said solenoid plunger is at
least approaching the end of its travel
3. The solenoid actuator of claim 1 wherein said switch exhibits a
time lag between said motion between said stationary member and
said moving member, and its switching of said first solenoid coil
lead between first and
4. The solenoid actuator of claim 1 further comprising a return
spring, said return spring being disposed between said stationary
member and said moving member so as to yieldably urge said moving
member from said first orientation to said second orientation with
respect to said stationary
5. The solenoid actuator of claim 2 further comprised of a source
of direct current having first and second terminals, a current
limiting means and a remote switching means schematically
representable as a single pole, double-throw switch having a moving
contact switchable between first and second fixed contacts, said
second solenoid coil lead being coupled to said moving contact of
said remote switch, said first and second actuator leads being
coupled to first and second terminals of said source of direct
current, respectively, said first fixed contact of said remote
switch being coupled to said first terminal of said source of
direct current and said second fixed contact of said remote switch
being coupled through said current limiting means, to said second
terminal of said source of direct
6. A solenoid actuator comprising a stationary member, a plunger, a
permanent magnet, a solenoid coil and a switch means, said plunger
and said stationary member forming a magnetic circuit having a
minimum air gap when said plunger is in the actuated position and a
maximum air gap when in the fully extended position, said permanent
magnet being disposed so as to form a portion of said magnetic
circuit and to be subject to magnetizing forces in said magnetic
circuit, said solenoid coil being disposed so as to cause a
magnetizing force on said magnetic circuit 99 when current is
passed through said coil, said switch means having first and second
terminals and being cooperatively disposed with respect to said
plunger and electrically coupled to a first end of said solenoid
coil so as to be operative to switch the coupling of said first end
of said solenoid coil from said first terminal to said second
terminal as said plunger moves toward said actuated position and
from said second terminal to said first terminal as said plunger
moves toward said fully extended
7. The solenoid actuator of claim 6 further comprising a return
spring, said return spring being disposed between said plunger and
said stationary member and being operative to return said plunger
to the fully extended position when the magnetic field in said
magnetic circuit is substantially less than the magnetic field
required to saturate said magnetic circuit.
8. The solenoid actuator of claim 6 wherein said switch means
comprises first and second fixed contacts connected to said first
and second terminals and a moving contact connected to said first
end of said
9. A solenoid actuator comprising: a generally cylindrical housing;
a magnetic plunger within said housing having an upwardly disposed
plunger face defined by a first outer diameter and an inner
diameter and adapted for vertical motion between an extended
position and an actuated position; a plunger rod of a second
diameter substantially less than said first outer diameter
connected to said plunger and extending through a clearance hole in
the bottom of said housing; a cylindrical magnetic member disposed
around said plunger, having a loose fit with said first outer
diamter, and extending upward therefrom; a solenoid coil having
first and second leads, located within and concentric to said
upward extending portion of said magnetic member; a magnetic pole
piece, having a clearance hole concentric therewith, disposed
within said solenoid coil and spaced above the upper end of said
plunger when said plunger is in said extended position; a permanent
magnet having a clearance hole concentric therewith disposed within
said solenoid coil and immediately above said pole piece; a
magnetic top plate having a clearance hole concentric therewith
disposed immediately above said solenoid coil and said permanent
magnet, and extending radially outward to a position adjacent said
upward extending portion of said cylindrical magnetic member; a
switch actuating pin disposed within said clearance holes in said
pole piece, said magnet and said top plate, and having an enlarged
head extending into said inner diameter of said plunger; a coil
spring disposed between said pole piece and said enlarged head on
said actuating pin and yieldably urging said actuating pin and said
plunger toward said extended position; and a single-pole,
double-throw switch mounted above said top plate and adapted for
actuation by said actuating pin, said switch being connected to
said first solenoid coil lead and adapted to switch electrical
coupling with said first solenoid coil lead between first and
second actuator leads in
10. The solenoid actuator of claim 9 wherein said switch has
mechanical hysteresis so that said switch will not switch
electrical coupling with said first solenoid coil lead between
first and second actuator leads until said plunger is at least
approaching the end of its travel at said
11. The solenoid actuator of claim 9 wherein said switch exhibits a
time lag between motion of said plunger and the switching of
electrical coupling with said first solenoid coil between first and
second actuator
12. The solenoid actuator of claim 9 further comprised of a source
of direct current having first and second terminals, a current
limiting means and a remote switching means schematically
representable as a single pole, double-throw switch having a moving
contact switchable between first and second fixed contacts, said
second solenoid coil lead being coupled to said moving contact of
said remote switch, said first and second actuator leads being
coupled to first and second terminals of said source of direct
current, respectively, said first fixed contact of said remote
switch being coupled to said first terminal of said source of
direct current and said second fixed contact of said remote switch
being coupled, through a current limiting means, to said second
terminal of said source of direct current.
Description
This invention relates to the field of solenoid actuators and the
method of actuation thereof.
2. Prior Art.
Solenoids are well-known electromechanical devices for the
conversion of electrical energy into mechanical energy, and
particularly into short stroke mechanical motion. These devices are
used to actuate valves, clutches and the like upon the application
of an electrical signal. In many applications, the efficiency of
the solenoid is of little concern since a relatively unlimited
source of electrical power is readily available. By way of example,
solenoids used in dishwashers for actuating valves, pumps and the
like are operated directly from a 115 volt power source for so long
as the solenoid is maintained in the actuated position, and power
dissipation, except as it effects solenoid size to avoid
overheating, is of little concern.
In other applications, the efficiency of the solenoid may be a
significant consideration. By way of example, solenoids may be used
in applications where the source of power is limited, such as, in
applications where the solenoid is to be operated by batteries. To
decrease the power dissipation by the solenoid, particularly in
applications where the solenoid is to be retained in the actuated
position for significant time periods, latching systems are used in
conjunction with the solenoids so that the solenoids may be
actuated by a relatively short term pulse to the solenoid coil and
latched in the actuated position without requiring further
electrical power application to the solenoid. Later, upon
application of a short unlatching signal, the latching system is
released and a return spring returns the solenoid plunger to the
fully extended position. Thus, the solenoid is actuated and latched
for an indefinitely long period by the application of only a short
duration pulse of electrical energy and may be unlatched for an
indefinite period by a similar unlatching pulse of electrical
energy.
In the prior art, one form of latching mechanism is comprised of a
permanent magnet forming part of the magnetic circuit of the
solenoid. The permanent magnet is thus subject to the magnetizing
and de-magnetizing forces of the solenoid coil and provides a form
of magnetic memory to retain either a high flux density, as
characteristic of the actuation conditions, or a low flux density
(approaching zero) characteristic of the unlatching condition.
Thus, to actuate and latch the solenoid, a high current pulse is
applied to the solenoid coil. This causes a strong magnetic field
between the stationary portion of the solenoid and the solenoid
plunger, with the magnetic field in the stationary portion also
passing through the permanent magnet. The magnetic forces on the
plunger attract the plunger into the fully actuated position and
the magnetizing force on the permanent magnet causes the permanent
magnet to be strongly charged. Thus, when the actuating current
pulse is removed, the permanent magnet maintains a substantial
portion of the magnetic field, thereby retaining the solenoid
plunger in the actuated position. To unlatch the solenoid so that
the return spring may move the solenoid plunger back to the fully
extended position, a current pulse is passed through the solenoid
coil in the opposite direction. This current pulse is selected to
be substantially less in magnitude than the actuating and latching
current pulse so that the permanent magnet is substantially
de-magnetized and the field in the solenoid reduced to a very low
level. In this condition, the return spring force is much greater
than the magnetic force and the soldnoid plunger is returned to the
fully extended position by the return spring.
Prior art solenoids of the latching variety as hereabove described
are highly efficient as compared to the non-latching solenoids
since power is not required to maintain the solenoid in the
actuated position after actuation has occurred. However, the
current pulses required to actuate the solenoid are not easily
generated and considerable additional complexity in the associated
circuitry is required in order to make the hereabove described
latching solenoids operate properly. The primary difficulty arises
from the fact that the current pulses for latching and unlatching
must be controlled (and different) in amplitude, of opposite
polarity and of timed duration. Consequently, timing circuitry,
polarity reversing circuitry and current determining circuitry must
be used with prior art latching solenoids having permanent magnet
latching systems therein in order to achieve the desired result.
The additional complexity of such circuitry substantially detracts
from the otherwise desirable features of such latching solenoids.
In this regard, it should be noted that because of the improved
efficiency of a latching solenoid over a solenoid of the
non-latching variety, smaller solenoids may be used for a specific
application without resulting in overheating of the solenoid. Thus,
such self-latching solenoids have the potential of being
substantially cheaper in a given application because of a
substantial reduction in size compared to the size of a
non-latching solenoid for the same application. This potential cost
reduction, however, is not realized in prior art actuating systems
because of the complexity of the circuitry required to provide the
required actuating and unlatching signals to the solenoid.
A self-latching solenoid actuator having a low power consumption
and an internal switching arrangement whereby latching and
unlatching may be accomplished by such means as a simple
single-pole, double-throw external switch and the like. The
solenoid has a permanent magnet in the magnetic circuit thereof so
that upon actuation by a high current in a first direction in the
solenoid coil, the plunger is pulled into the actuated position and
the permanent magnet is charged, thereby magnetically retaining the
plunger in the actuated position. When a smaller current is passed
through the solenoid coil in the opposite direction, the magnetic
field holding the solenoid in the actuated position is reduced to
approximately zero so that a return spring may force the plunger to
the fully extended position. A switching means is disposed adjacent
the solenoid stationary member and a member actuated by the plunger
extends through the end of the stationary member so as to engage
the switching means. The switch is a single-pole, double-throw
switch with the moving contact attached to one end of the coil and
each of the two remaining contacts attached to each of the power
supply terminals. By attaching the other end of the solenoid coil
to the equivalent of the moving member of an external single-pole,
double-throw switch and attaching the equivalent of the two
stationary contacts of the external switch to the power supply
terminals, the solenoid may be caused to be actuated and unlatched
in response to the condition of the external switch. The internal
switch limits the power drain to that required for actuation and
unlatching and maintains the steady-state power drain at zero. Two
embodiments of the invention are disclosed.
FIG. 1 is a perspective view of one embodiment of the self-latching
solenoid actuator of the present invention.
FIG. 2 is a cross-section of the solenoid actuator of the present
invention taken along lines 2--2 of FIG. 1.
FIG. 3 is a schematic diagram showing the electrical connection of
the solenoid actuator of the present invention to a source of
electrical power and remote control of the actuator.
FIG. 4a is a schematic diagram representing the cross-section of
the magnetic circuit of the solenoid actuator of the present
invention, illustrating the relatively weak magnetic field in the
magnetic circuit when the solenoid is in the unlatched
condition.
FIG. 4b is a schematic diagram representing the cross-section of
the magnetic circuit of the solenoid actuator of the present
invention, illustrating the strong magnetic field in the magnetic
circuit holding solenoid actuator in the latched position.
FIG. 5 is a B-H curve typical of permanent magnet materials
illustrating the magnetic field density and magnetizing force for
various points throughout the operation of the solenoid actuator of
the present invention.
FIG. 6 is a cross-section of an alternate embodiment of the
solenoid actuator of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
First referring to FIG. 1, a perspective view of the present
invention solenoid may be seen. The solenoid of this embodiment is
characterized by a cylindrical body 20, a plunger rod 34 extending
outward from the cylindrical body, and three wires 24, 26 and 28
extending outward generally from the top of the solenoid.
Now referring to FIG. 2, a cross-section taken along lines 2--2 of
FIG. 1 may be seen. The various components of the solenoid are
housed within housing 30 (forming cylindrical body 20) which
provides an outer protective case and may be adapted as desired for
mounting of the solenoid. A plunger 32 is disposed adjacent one end
of the case, with an integral plunger rod 34 projecting through an
opening in the end of the case for attachment to the mechanism to
be actuated by the solenoid. A soft iron inner case member 36 has
an inner diameter 38 forming a loose slip fit with the outer
diameter of the plunger 32, and has an integral, upward projecting
cylindrical member 40 forming a portion of the magnetic circuit and
providing an inner diameter for location of other components of the
solenoid. Fitting within the upward projecting member 40 is a
solenoid coil 42 wound on a plastic bobbin 44. A non-magnetic
spacer 46 fits within the inside diameter of plastic bobbin 44 and
spaces a soft iron pole piece 48 above the inner end 50 of the
plunger 32. Located above the pole piece 48 is a permanent magnet
52, the top surface of which is substantially flush with the top of
the plastic bobbin 44. A soft iron upper frame member 54 fits
within the upward projecting member 40 so as to complete the
magnetic circuit and to retain the various components of the
solenoid in cooperative disposition.
Located above the upper frame member is a non-magnetic spacer 56,
and located thereabove at the top of the outer case member 30 is a
single-pole, double-throw switch 58 having a centrally disposed
actuating member 60. The switch 58, of the type often referred to
as microswitches, is retained in position by cementing the switch
in place in the case member 30 (as are the other parts of the
solenoid).
The plunger 32 has a cylindrical depression 62 extending downward
from the top face 50 of the plunger and adapted to receive the
switch actuating pin 64. The switch actuating pin 64, which is a
non-magnetic pin, has an enlarged head 66 at the lower end thereof
fitting within cylindrical depression 62 in plunger 32, and extends
upward through clearance holes in pole piece 48, magnet 52, upper
frame member 54 and the spacer 56 to a position adjacent switch
actuating member 60. A coil spring 68 disposed between pole piece
48 and the enlarged head 66 on switch actuating pin 64 urges the
switch actuating pin and plunger 32 into the downward position
shown in FIG. 2. This position shall be referred to herein as the
fully extended position.
The various parts of the solenoid are assembled by merely slipping
them in the proper order into the top of case member 30 and
cementing various of the parts to the case member so as to retain
the assembly in position. The two leads for solenoid coil 42 may be
brought out through appropriate openings in the side of member 40
and case member 30, or, as is done in the preferred embodiment, may
be brought upward through appropriately placed grooves in pole
piece 54 and cooperative holes in spacer 56 to positions adjacent
switch 58. This last specified manner of bringing out the two
solenoid coil leads is preferred because it disposes the leads
adjacent the switch and, as shall be subsequently seen, one of such
leads is connected to one of the switch terminals.
Having described the structure of the solenoid of the present
invention, the electrical connection of the solenoid and operation
thereof shall now be described with the aid of FIG. 3. One end 41
of the solenoid coil 42 is connected to the moving contact 70 of
switch 58 in the solenoid (generally indicated by the dashed
enclosure 72 of FIG. 3). The other end of the solenoid winding is
brought out of the solenoid on line 24 and the two switch contacts
for switch 58 are brought out on lines 26 and 28. Thus, the
solenoid of the present invention has three electrical connections
thereto, rather than simply two electrical connections
characteristic of the prior art devices. Leads 26 and 28 are
connected to each side of a DC power source 74 and lead 24 is
connected to the moving contact 76 of a single-pole, double-throw
switch, generally indicated by the numeral 78. One contact of the
switch is connected to the power source 74 and the other contact is
connected through a resistor 80 to the other side of the power
source. It is to be understood that the single-pole, double-throw
switch 78 is schematic only, and in any specific application of the
present invention might be comprised of a mechanical switch, an
electronic switch or like devices.
With switch 78 in the position shown in FIG. 3, the solenoid
plunger will be in the fully extended position, as shown in FIG. 2,
and microswitch 58 will also be in the position shown in FIG. 3.
Thus, both ends of the solenoid coil 42 are connected to the same
side of the DC power source 74. Consequently, the power drain from
the power source 74 in this unlatched state is zero. In this
condition, there will be a small magnetic field in the solenoid,
generally indicated by the field lines 82 in FIG. 4a (which is a
schematic representation of the magnetic circuit in the solenoid
when in the fully extended position). The strength of the magnetic
field at this time is quite low, as shall be subsequently described
in detail, being on the order of 5 to 10 percent of the saturation
values for the circuit. Since the magnetic force exerted on the end
50 of plunger 32 by the magnetic field between the plunger and the
pole member 48 is proportional to the square of the field strength,
the magnetic force exerted on the plunger is on the order of 1
percent of the maximum force achievable. The return spring 68, on
the other hand, which is under substantial preload, has a force
approximately equal to one-half the maximum force of the solenoid,
and, therefore, plunger 32 is encouraged to remain in the position
shown by the return spring.
When switch 78 is first switched to the position shown in phantom
in FIG. 3, line 24 is connected to the positive side of the power
source 74 while the other end of coil 42 is connected through line
28 to the negative side of the power source. Consequently, the full
voltage of power source 74 is connected to the solenoid coil 42 and
a high magnetizing current is caused to flow in the coil. This
creates a high magnetizing force in the magnetic circuit, causing a
high flux density both through permanent magnet 52 and through the
air gap between pole piece 48 and plunger 32. In general, it is
desirable for the current in coil 42 to result in a sufficient
magnetizing force to nearly saturate the soft iron in the magnetic
circuit and to substantially fully magnetize the permanent magnet
52. Under this condition, the solenoid force will be approximately
twice the return spring force and the solenoid plunger will move to
the position shown in FIG. 4b and as shown in phantom in FIG. 2.
This position shall be referred to herein as the fully actuated or
latched position for the solenoid. As the plunger approaches the
position shown, the switch actuating member 64 (FIG. 1) operates
the switch 58, causing the switch to change to the position shown
in phantom in FIG. 3. When the switch 58 changes to this position,
the current in coil 42 falls to zero, since both ends of the coil
are again attached to the same terminal of the power source 74 (in
this case the positive terminal). However, since the permanent
magnet 52 was substantially fully magnetized by the sharp pulse of
current to the solenoid coil, and since the current pulse
terminated only as the air gap in the magnetic path approached a
very small value, there is little demagnetizing force present to
cause a demagnetization of the permanent magnet. Therefore, the
field remains at a very high level as indicated by the field lines
84 in FIG. 4b, the magnetic force remains substantially equal to
twice the return spring force, and the plunger is latched in the
position shown in FIG. 4b. Thus, the solenoid has been actuated,
caused to latch in the actuated position, and has been disconnected
from further power drain merely upon a single external switching
signal.
The solenoid is changed from the latched condition shown in FIG. 4
to the unlatched and fully extended position as shown in FIGS. 2
and 4a by moving external switch 78 from the position shown in
phantom back to the original position. Since microswitch 58
initially remains in the position shown in phantom in FIG. 3,
opposite ends of the coil 42 are again connected to opposite poles
of the power source 74. However, in this case line 24 is connected
to the negative side of the power source and the other end of coil
42 is connected to the positive side of the power source through
line 26. Thus, the polarity of the electrical connection to the
solenoid coil 42 is reversed over that which initially caused the
high field strength 84 as shown in FIG. 4b. Consequently, the
current flowing through the solenoid coil 42 causes a substantial
de-magnetizing force on the permanent magnet 52. If this current
were not limited, the net effect would be to demagnetize and
re-magnetize permanent magnet 52 with the opposite polarity, and
since magnetic force is proportional to the square of the field, a
reversal of field polarity would result in no change in the
magnetic force. However, the de-magnetizing current is limited by
resistor 80 so that the permanent magnet 52 is not re-magnetized
with the opposite polarity as that shown 4b. FIG. 4b. Instead,
resistor 80 is chosen so that the de-magnetizing force created by
the current flowing in coil 42 is substantially equal to the
de-magnetizing force required to reduce the field in the magnetic
circuit, and particularly in the permanent magnet, to a value
substantially equal to zero. Thus, the magnetic force from the
solenoid falls to substantially zero and the return spring returns
the solenoid plunger to the position shown in FIG. 4a. As the
plunger returns, the switch actuating member 64 allows switch 58 to
switch back to its original position as shown in FIG. 3, thus
terminating the de-magnetizing current pulse and again connecting
both ends of solenoid coil 42 to the same side of power source 74,
namely, the negative terminal.
When the de-magnetizing current is switched off as hereinabove
described, the permanent magnet will cause a small percentage of
the maximum magnetic field to return to the magnetic circuit.
However, the extent to which the magnetic field increases when the
de-magnetizing current is switched off may be controlled by the
proper design of the solenoid and, in general, will not be adequate
to prevent the desired unlatching of the solenoid.
The design considerations for the design of a solenoid of the
present invention having the greatest latching force and the
greatest unlatching ability may be described with the aid of FIG.
5. This figure is a typical de-magnetization curve for a permanent
magnet material, the curve shown being generally representative of
the grain oriented alnico V materials. It is to be understood,
however, that other permanent magnet materials may also be used
with the solenoids of the present invention by appropriate design
of the solenoid magnetic circuit, though alnico V is used in the
preferred embodiment because of its high energy product, its high
saturation flux density and its moderate magnetizing and
de-magnetizing force requirements. In FIG. 5, the ordinate is the
flux density B and the abscissa is the de-magnetizing force H. When
the solenoid is first actuated, the high current in the solenoid
winding 42 results in a high magnetizing force in the magnetic
circuit. Initially, this magnetizing force is divided, part of it
being required to cause a high flux density in the air gap between
the plunger and the stationary portion of the solenoid and part of
it, for reasons to subsequently become apparent, being required to
cause the relatively high flux density in the permanent magnet. As
the plunger moves toward the actuated position, the magnetizing
force required to sustain the high magnetic field in the air gap
reduces proportionately, so that a greater percentage of the
magnetizing force is concentrated in the permanent magnet. In order
to insure that the permanent magnet is well magnetized without
requiring an excessive magnetizing current in the solenoid coil, it
is desirable to design the various components of the solenoid so
that the switch 58 will turn off the magnetizing current as
hereinabove described only as the plunger approaches the latched
position. This assures that only a small percentage of the
magnetizing force is required to maintain the flux density in the
air gap and most of the magnetizing force is impressed on the
permanent magnet. This provides the most efficient use of the
available magnetizing force which, for a given solenoid design, is
a measure of the power dissipation in the solenoid coil. Under
these conditions, the permanent magnet will have the flux density
and be subject to the magnetizing force indicated by point 86 in
FIG. 5.
Typically, the flux density at saturation, that is, at point 86, is
somewhat less than the saturation flux density for the soft iron
components in the solenoid. Thus, since the magnetic force is
proportional to the square of the flux density times the area over
which the flux density is distributed, the solenoid force at
saturation of the permanent magnet may be increased if the flux
between the plunger and the fixed portion of the solenoid is
distributed over a smaller area than the flux through the permanent
magnet. In general, the plunger iron should saturate at
substantially the same total field strength as the permanent
magnet. Thus, it may be noted in FIG. 2 that the area of surface 50
of the plunger 32 is substantially smaller than the cross-section
of magnet 52, the ratio of these areas being dependent upon the
permanent magnet material chosen for magnet 52.
When switch 58 actuates so as to turn off the magnetizing current,
the operating point of the permanent magnet will move along line 88
to point 90, determined by the intersection of line 88 and line 92.
Line 92 is, in essence, a measure of the air gap in the magnet
circuit at the instant that the magnetizing current is terminated
and may be approximated by the equation
B = HAglm/A.sub.m l.sub.g where B is the flux density in the
magnet; where H is the magnetizing (de-magnetizing) force in the
permanent magnet; where Ag is the cross-sectional area of the air
gap between the plunger and the stationary portion of the solenoid
(e.g., the cross-sectional area of the plunger face); where lm is
the length of the magnet as measured in the direction of the field
through the magnet; where A.sub.m is the cross-sectional area of
the magnet measured perpendicular to the field; and where l.sub.g
is the length of the air gap between the plunger face and the
stationary portion of the solenoid.
Thus, it may be seen that when the actuating current is switched
off the flux density in the solenoid will drop somewhat depending
in part upon the air gap length l.sub.g at that time. If the air
gap is small, the flux density will remain relatively high and
similarly the solenoid force will remain relatively high. The
plunger will continue moving to the latched position as a result of
the high flux density maintained by the permanent magnet, and at
the latched position, since the air gaps in the magnetic circuit
are then small, the flux density will approach the value at point
94.
From the above description, it is apparent that the solenoid force
is lowest during actuation at the instant that the actuating
current is switched off, and this force may be caused to be as high
as possible by designing the solenoid so that the actuating current
does not switch off until the air gap between the plunger and pole
piece 48 is approaching zero.
When the external switch 78 is switched to the unlatching position,
a de-magnetizing current is caused to flow in the solenoid coil.
This current is limited by resistor 80 so as to cause a
de-magnetizing force approximately equal to that indicated at point
96, which in turn causes the magnetic field in the solenoid to go
substantially to zero. In this condition, as hereinbefore
described, the return spring 68 urges the plunger 32 toward the
fully extended position, and as the plunger approaches the fully
extended position causes switch 58 to turn off the de-magnetizing
current. When this occurs the flux density in the magnetic circuit
will increase to the value existing at point 98, determined by the
intersection of line 100 (having a slope approximately equal to the
slope of line 88 at point 94 and representing a physical
characteristic of the permanent magnet material) and line 102
determined by the same equation as line 92 but having a much
shallower slope because of the greatly increased air gap at this
time. The flux density at point 98 will result in a small magnetic
force opposing the return spring force, thereby reducing the net
force urging the plunger to the unlatched position. This force,
however, being proportional to the square of the field strength,
will be relatively small and may be caused to be a minimum by
assuring in the design of the solenoid that the de-magnetizing
current causes the flux density in the solenoid to approach zero
(e.g., to have a small plus or minus value) and by assuring that
the de-magnetizing current remains until the plunger is near the
fully extended position, that is, until the air gap l.sub.g is near
its maximum value. Thus, it may be seen from the above description
of the latching and unlatching of the solenoid actuator of the
present invention that it is desirable, though not absolutely
necessary, that the switch 58 be caused to have a certain amount of
mechanical hysteresis as is typical of switches of a suitable type
that are commercially available, or, in the alternative, a small
time lag so that it will not switch during the travel of the
solenoid plunger in either direction until the plunger is near or
at the end of that travel. Such action of the switch assures
maximum latching and minimum unlatching forces for a solenoid of a
given size.
When the latching current is again applied to the solenoid coil and
the magnetizing force increases, the operating point for the magnet
will move from point 98 along line 104 to point 86, again
substantially saturating the permanent magnet and the solenoid
iron, at least in the vicinity of the plunger face.
Now referring to FIG. 6 an alternate embodiment of the present
invention solenoid may be seen. In this embodiment, the design of
the solenoid is very similar to that of the embodiment illustrated
in FIGS. 1 and 2. In particular, the elements of the solenoid,
identified by numbers followed by the letter "a," are similar in
design and function to the elements identified by the same numbers
and described with respect to FIG. 2, and, therefore, a detailed
description of the design and function of most of these parts will
not be herein repeated. It should be noted, however, that in this
design the plunger 32 and plunger rod 34 are not integral, but
instead comprise an assembly of two pieces. Similarly, the soft
iron inner case member 36a and the upward projecting cylindrical
member 40a are not integral members, but again are an assembly of
two separate pieces. The upper frame member 54a has a slot,
generally indicated by the numberal 120, in which one of the leads
of the solenoid coil 42a is disposed. The other solenoid lead is
brought out through a slot in the upward projecting cylindrical
member 40a and a hole in the housing 30a as lead 24a. Lead 26a
passes through a second hole in housing 30a and is electrically
attached to the electrically conductive housing so as to provide
electrical contact through the various other conductive parts of
the solenoid, and particularly through coil spring 68a and
actuating pin 64a. An electrically insulative element 122 provides
a support for conductive contact surface 124, connected to lead 28a
through a third hole in the housing 30a, and also provides a
support for a leaf switch member 126. Thus, with the solenoid in
the fully extended position, as shown in FIG. 6, the solenoid coil
42a is electrically connected to leads 24a and 28a, but upon
actuation of the solenoid the switch actuating pin 64a makes
electrical contact with the leaf switch member 126, and
simultaneously elastically deflects the switch member so that it no
longer makes electrical connection with contact surface 124.
Consequently, the solenoid coil 42 is then connected between leads
24a and leads 26a, thereby providing for the operation and
switching of the solenoid coil connections as hereinbefore
described, particularly with respect to FIG. 3.
Other embodiments, and in particular, other arrangements for the
solenoid actuated switching of the solenoid lead connections, will
be obvious to those skilled in the art. By way of specific example,
the principles of the present invention may be applied to rotary
solenoids, using either a cam actuated switch, such as switch 58,
or a rotary switch well-known in the art of mechanical switching
devices. Similarly, while the schematic representation of FIG. 3
suggests the operation of the solenoid of the present invention
directly from an electrical source 74, such as a battery, other
sources of electrical power may readily be used with the present
invention, such as a capacitor storage system comprising a battery
connected through a resistor to a capacitor so that the solenoid is
latched and unlatched by the discharge of the capacitor, thereby
providing a higher instantaneous current level than would be
possible with a small battery, yet resulting in a very low total
energy withdrawal from the battery. Thus, while the invention has
been particularly shown and described with reference to preferred
embodiments thereof, it will be understood by those skilled in the
art that various changes in form and detail may be made therein
without departing from the spirit and scope of the invention.
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