WO2013032554A1 - Low eddy current intensifier control valve - Google Patents

Low eddy current intensifier control valve Download PDF

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Publication number
WO2013032554A1
WO2013032554A1 PCT/US2012/041558 US2012041558W WO2013032554A1 WO 2013032554 A1 WO2013032554 A1 WO 2013032554A1 US 2012041558 W US2012041558 W US 2012041558W WO 2013032554 A1 WO2013032554 A1 WO 2013032554A1
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WO
WIPO (PCT)
Prior art keywords
spool
control valve
main body
electrically conductive
contact surface
Prior art date
Application number
PCT/US2012/041558
Other languages
French (fr)
Inventor
Grzegorz Siuchta
Dean Alan Oppermann
Original Assignee
International Engine Intellectual Property Company, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by International Engine Intellectual Property Company, Llc filed Critical International Engine Intellectual Property Company, Llc
Publication of WO2013032554A1 publication Critical patent/WO2013032554A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M63/00—Other fuel-injection apparatus having pertinent characteristics not provided for in groups F02M39/00 - F02M57/00 or F02M67/00; Details, component parts, or accessories of fuel-injection apparatus, not provided for in, or of interest apart from, the apparatus of groups F02M39/00 - F02M61/00 or F02M67/00; Combination of fuel pump with other devices, e.g. lubricating oil pump
    • F02M63/0012—Valves
    • F02M63/0014—Valves characterised by the valve actuating means
    • F02M63/0015—Valves characterised by the valve actuating means electrical, e.g. using solenoid
    • F02M63/0017—Valves characterised by the valve actuating means electrical, e.g. using solenoid using electromagnetic operating means
    • F02M63/0019—Valves characterised by the valve actuating means electrical, e.g. using solenoid using electromagnetic operating means characterised by the arrangement of electromagnets or fixed armatures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M57/00—Fuel-injectors combined or associated with other devices
    • F02M57/02—Injectors structurally combined with fuel-injection pumps
    • F02M57/022—Injectors structurally combined with fuel-injection pumps characterised by the pump drive
    • F02M57/025—Injectors structurally combined with fuel-injection pumps characterised by the pump drive hydraulic, e.g. with pressure amplification
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M59/00—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps
    • F02M59/02—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps of reciprocating-piston or reciprocating-cylinder type
    • F02M59/10—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps of reciprocating-piston or reciprocating-cylinder type characterised by the piston-drive
    • F02M59/105—Pumps specially adapted for fuel-injection and not provided for in groups F02M39/00 -F02M57/00, e.g. rotary cylinder-block type of pumps of reciprocating-piston or reciprocating-cylinder type characterised by the piston-drive hydraulic drive
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M63/00—Other fuel-injection apparatus having pertinent characteristics not provided for in groups F02M39/00 - F02M57/00 or F02M67/00; Details, component parts, or accessories of fuel-injection apparatus, not provided for in, or of interest apart from, the apparatus of groups F02M39/00 - F02M61/00 or F02M67/00; Combination of fuel pump with other devices, e.g. lubricating oil pump
    • F02M63/0012—Valves
    • F02M63/0031—Valves characterized by the type of valves, e.g. special valve member details, valve seat details, valve housing details
    • F02M63/004—Sliding valves, e.g. spool valves, i.e. whereby the closing member has a sliding movement along a seat for opening and closing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M63/00—Other fuel-injection apparatus having pertinent characteristics not provided for in groups F02M39/00 - F02M57/00 or F02M67/00; Details, component parts, or accessories of fuel-injection apparatus, not provided for in, or of interest apart from, the apparatus of groups F02M39/00 - F02M61/00 or F02M67/00; Combination of fuel pump with other devices, e.g. lubricating oil pump
    • F02M63/0012—Valves
    • F02M63/0059—Arrangements of valve actuators
    • F02M63/0063—Two or more actuators acting on a single valve body
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K31/00—Actuating devices; Operating means; Releasing devices
    • F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
    • F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
    • F16K31/0603—Multiple-way valves
    • F16K31/061—Sliding valves
    • F16K31/0613—Sliding valves with cylindrical slides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K31/00—Actuating devices; Operating means; Releasing devices
    • F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
    • F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
    • F16K31/0675—Electromagnet aspects, e.g. electric supply therefor
    • F16K31/0679—Electromagnet aspects, e.g. electric supply therefor with more than one energising coil
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00—Magnets
    • H01F7/06—Electromagnets; Actuators including electromagnets
    • H01F7/08—Electromagnets; Actuators including electromagnets with armatures
    • H01F7/16—Rectilinearly-movable armatures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F7/00—Magnets
    • H01F7/06—Electromagnets; Actuators including electromagnets
    • H01F7/08—Electromagnets; Actuators including electromagnets with armatures
    • H01F7/16—Rectilinearly-movable armatures
    • H01F2007/1676—Means for avoiding or reducing eddy currents in the magnetic circuit, e.g. radial slots

Definitions

  • the field of the disclosure relates to fuel injection systems for internal combustion engines and, more particularly, to intensifier control valves for fuel injection systems.
  • Contemporary fuel injection systems may be built around electromagnetically actuated valves including intensifier control valves.
  • Elements of these devices such as cores of a electro-magnet actuators and spools, may be made of electrically conductive material which is exposed to the time -varying magnetic flux from the wire coils of the actuators. Eddy currents in the core weaken the magnetic field applied to the spool. The spool's movement in and out time-varying magnetic fields which produces eddy currents in the spool which resist movement in the direction which the field generated by the coil is intended to induce. These factors negatively affect performance of the valve. The consequences are slow movement of the spool and possible sticking of the valve in high viscosity environments.
  • a control valve has a main body, a close coil assembly located on a first side of the main body which has a contact surface and an open coil assembly located on a second side of the main body having a contact surface.
  • a spool is arranged in the main body and configured for movement between the contact surfaces of the close and open coil assemblies.
  • the close and open coil assemblies comprise first and second electrically conductive ferro-magnetic cores with first and second wire coils surrounding the cores.
  • the first and second electrically conductive ferro-magnetic cores have a longitudinal dimension with a plurality of electrically insulating resin filled slots parallel thereto.
  • the spool includes at each of two ends proximate the contact surfaces of the coil assemblies, a plurality of longitudinal, electrically insulating resin filled slots arranged to extend radially from the central axis of the spool and extending longitudinally inwardly from the ends of the spool.
  • the resin filled slots serve to isolate and diminish the intensity of the eddy current development in the cores and in the spool.
  • FIG. 1 is a longitudinal cross sectional view of a control valve body including a pair of solenoid coil assemblies and a spool.
  • FIG. 2 is a graph illustrating the relationship of solenoid coil assembly current versus induced electromagnetic field.
  • FIG. 3 is a perspective view of a solenoid coil assembly.
  • FIGS. 4A-B are latitudinal cross sectional and end views, respectively, of a solenoid coil assembly.
  • FIGS. 5A-B are latitudinal cross sectional and end views, respectively, of a solenoid coil assembly modified to suppress development of eddy currents.
  • FIG. 6 is an enlarged end view of a ferro-magnetic core from the solenoid coil assembly of FIG. 4A.
  • FIG. 7 is an enlarged end view of a ferro-magnetic core from the solenoid coil assembly of FIG. 5A.
  • FIGS. 8A-B are a cross sectional and end views, respectively of a spool.
  • FIGS. 9A-B are a cross sectional and end views, respectively of a spool.
  • FIG. 1 shows a cross sectional view of an intensifier control valve body 100.
  • the intensifier control valve body 100 may include an inlet area 102.
  • the inlet area 102 may be connected for fluid communication with working ports 104.
  • At least one groove or orifice 106 (hereafter "grooves") may be positioned between, and in fluid communication with, the inlet area 102 and the working ports 104.
  • a spool 110 having at least one groove 108 may be slidably mounted withm the intensifier control valve body 100.
  • the spool 110 may have a contact surface 110A and a second contact surface HOB at its respective ends. Further, the spool 100 may a longitudinal through hole HOC extending from the first contact surface to the second contact surface.
  • a close coil assembly 130 and an open coil assembly 140 may be positioned on opposing sides of the spool 110, respectively.
  • the close coil assembly 130 may have a contact surface 132 at one side thereof.
  • the first contact surface 110A of the spool may contact the contact surface 132 when the spool 110 moves toward and contacts the close coil assembly 130.
  • the close coil assembly 130 may further have a through hole 134 extending from the contact surface 132 to the opposite side thereof.
  • the open coil assembly 140 may have a contact surface 142 at one side thereof.
  • the second contact surface HOB of the spool 110 may contact the contact surface 142 when the spool 110 moves towards and contacts the open coil assembly 140.
  • the open coil assembly 140 may have a through hole 144 extending from the contact surface 142 to the opposite side thereof.
  • a bolt 112 may be arranged through the through holes 134, HOC, 144 for slidably mounting the spool 110 to the control valve body 100.
  • the through holes 134, HOC, 144 may be aligned and have the same diameter.
  • FIG. 2 illustrates the relationship of potted winding 150 current to a resultant magnetic field strength. Though the eddy current, and its resultant magnetic field, decay quickly due to resistance losses, there is a time delay in achieving full magnetic field strength without initially overdriving current into a winding 150.
  • FIG. 3 illustrates the location of eddy current in a ferro-magnetic core 152 A and the opposed directions of the primary magnetic field induced by current flowing in the winding 150 and the eddy current magnetic field produced by current flow in the core 152 A.
  • FIGS. 4A-B and 5A-B provide more detailed cross sectional views of the open coil assembly 140A-B illustrating modification of the assembly to suppress development of eddy currents in a ferro-magnetic core 152B of an intensifier control valve body 100 when the intensifier control valve body 100 is in use.
  • Eddy currents are generated m electrically conductive elements proximate to time-varying electro-magnetic fields or which are moving with respect to an electro-magnetic field.
  • Electro-magnetic fields are generated in the close coil assembly 130 and open coil assemblies 140A, B.
  • the open coil assemblies 140A, B each comprise a potted magnet wire winding 150 on ferro-magnetic cores 152A, B.
  • Ferro-magnetic cores 152A, B may be made of an electrically conductive material.
  • a face from each of ferro-magnetic cores 152A, B is juxtaposed one or the other ends of spool 110.
  • Spool 110 may also be made of an electrically conductive material and is moved by time-varying magnetic fields. Ferromagnetic core 152A, B and spool 110 are positioned closely enough to potted magnet wire winding 150 for eddy currents to be generated in the core and the valve stemming from magnetic flux produced by the winding.
  • Modification of the open coil assembly 140B of FIG. 2B as compared to the open coil assembly 140A includes resin filled insulation slots 154 in ferro-magnetic core 152B. Filled insulation slots 154 electrically isolate sub-regions within the ferromagnetic core 152B which in turn localizes any eddy currents which are generated as a consequence of time-varying magnetic flux produced by the winding 150. This isolates eddy currents into smaller regions which can reduce the strength of the reactive, opposing magnetic fields produced by the eddy currents which result in a corresponding reducing the strength of the overall magnetic field operating on the spool 110.
  • the close coil assembly 130 may be similarly modified.
  • Filled insulation slots 154 in ferro-magnetic core 152B are constructed by machining radial slots from the inside face of the magnetic core to at least the depth of the potted winding 150 and potentially for the full length of ferro-magnetic core 152B.
  • the direction of the insulation slots 154 is generally parallel to the direction of the induced magnetic field.
  • the machined slot is then filled with an electrically insulating material, typically a resin.
  • four filled insulation slots 154 are provided for each of close coil assembly 130 and open coil assembly 140 although more or fewer such slots can be provided, tor however many slots 154 are used, they may conveniently radially oriented and distributed spaced evenly around the core.
  • FIGS. 6 and 7 isolate and expand on an end view of the ferro-magnetic core 152A-B in order to illustrate the change between cores 152 A (no eddy current suppression) and 152B in greater detail.
  • Eddy currents can also be generated near the ends of the spool 110. Eddy currents induced by the primary magnetic field are mitigated somewhat by resultant magnetic fields, however the net field can result in fields being generated by spool eddy currents which oppose the primary field.
  • Spool 110 is modified by incorporation of filled insulated slots 160 introduced from each of end faces 110A, HOB of spool 110. Again the filled insulated slots are radially distributed evenly around the spool. Spool 110 is shown with four such insulated slots 160. The insulated slots break up the ends of the spool 110 into mutually isolated regions in which eddy currents develop.
  • the elongated, filled, electrically insulating slots disposed in spool 110 and cores 152A-B function as interstitial boundaries within the spool and cores and reduce the volume of material in which eddy currents circulate and thereby limit or suppress their development. This reduces the strength and duration of the resultant magnetic fields produced by the eddy currents.
  • Valve body 100 operation should be quicker and more consistent with suppression of eddy currents. The ill effects of cold start operation, dirty oil operation and worn injector operation can also be mitigated.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Power Engineering (AREA)
  • Magnetically Actuated Valves (AREA)

Abstract

A control valve has a main body, a close coil assembly comprising a first contact surface and an open coil assembly comprising a second contact surface. A spool moves between the first and second contact surfaces. The coil assemblies comprise first and second electrically conductive ferro-magnetic cores with first and second wire coils wound thereon, respectively. The first and second ferro-magnetic cores each have a plurality of resin filled slots providing electrically insulated boundaries within the cores to mitigate eddy current development. The spool includes a plurality of resin filled longitudinal slots extending inwardly from the ends of the spool for the same function.

Description

LOW EDDY CURRENT INTENSIFIER CONTROL VALVE
PRIORITY CLAIM
This application claims the benefit of U.S. Provisional Patent Application No.
61/530,502 filed 2 September 2011.
BACKGROUND
[001] Technical Field:
[002] The field of the disclosure relates to fuel injection systems for internal combustion engines and, more particularly, to intensifier control valves for fuel injection systems.
[003] Description of the Technical Field:
[004] When a electrically conductive material is subjected to a time-varying magnetic flux, eddy currents are produced in the conductive material. The resulting eddy currents generate a time-varying magnetic field of opposite polarity to the outside time -varying flux. The interaction of the magnetic fields produces a force that resists the change in the magnetic flux.
[005] Contemporary fuel injection systems may be built around electromagnetically actuated valves including intensifier control valves. Elements of these devices, such as cores of a electro-magnet actuators and spools, may be made of electrically conductive material which is exposed to the time -varying magnetic flux from the wire coils of the actuators. Eddy currents in the core weaken the magnetic field applied to the spool. The spool's movement in and out time-varying magnetic fields which produces eddy currents in the spool which resist movement in the direction which the field generated by the coil is intended to induce. These factors negatively affect performance of the valve. The consequences are slow movement of the spool and possible sticking of the valve in high viscosity environments. [006] The detrimental effects of eddy current generation in electro-magnetic actuators for engine intake and exhaust valves were recognized by D'Alpaos et al. in United States Patent No. 6,798,636. D'Alpaos observed that it had been proposed to make actuator bodies from materials which were ferro-magnetic but not electrically conductive or from laminated ferromagnetic material. D'Alpaos criticized such approaches and proposed as an alternative the modeling the eddy currents in order to compensate for the effect.
SUMMARY
[007] A control valve has a main body, a close coil assembly located on a first side of the main body which has a contact surface and an open coil assembly located on a second side of the main body having a contact surface. A spool is arranged in the main body and configured for movement between the contact surfaces of the close and open coil assemblies. The close and open coil assemblies comprise first and second electrically conductive ferro-magnetic cores with first and second wire coils surrounding the cores. The first and second electrically conductive ferro-magnetic cores have a longitudinal dimension with a plurality of electrically insulating resin filled slots parallel thereto. The spool includes at each of two ends proximate the contact surfaces of the coil assemblies, a plurality of longitudinal, electrically insulating resin filled slots arranged to extend radially from the central axis of the spool and extending longitudinally inwardly from the ends of the spool. The resin filled slots serve to isolate and diminish the intensity of the eddy current development in the cores and in the spool.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] FIG. 1 is a longitudinal cross sectional view of a control valve body including a pair of solenoid coil assemblies and a spool.
[009] FIG. 2 is a graph illustrating the relationship of solenoid coil assembly current versus induced electromagnetic field. [0010] FIG. 3 is a perspective view of a solenoid coil assembly.
[0011] FIGS. 4A-B are latitudinal cross sectional and end views, respectively, of a solenoid coil assembly.
[0012] FIGS. 5A-B are latitudinal cross sectional and end views, respectively, of a solenoid coil assembly modified to suppress development of eddy currents.
[0013] FIG. 6 is an enlarged end view of a ferro-magnetic core from the solenoid coil assembly of FIG. 4A.
[0014] FIG. 7 is an enlarged end view of a ferro-magnetic core from the solenoid coil assembly of FIG. 5A.
[0015] FIGS. 8A-B are a cross sectional and end views, respectively of a spool.
[0016] FIGS. 9A-B are a cross sectional and end views, respectively of a spool.
DETAILED DESCRIPTION
[0017] In the following detailed description, like reference numerals and characters may be used to designate identical, corresponding, or similar components in differing drawing figures. Furthermore, example sizes/models/values/ranges may be given with respect to specific embodiments but are not to be considered generally limiting.
[0018] Referring now to the figures, FIG. 1 shows a cross sectional view of an intensifier control valve body 100. The intensifier control valve body 100 may include an inlet area 102. The inlet area 102 may be connected for fluid communication with working ports 104. At least one groove or orifice 106 (hereafter "grooves") may be positioned between, and in fluid communication with, the inlet area 102 and the working ports 104. A spool 110 having at least one groove 108 may be slidably mounted withm the intensifier control valve body 100. The spool 110 may have a contact surface 110A and a second contact surface HOB at its respective ends. Further, the spool 100 may a longitudinal through hole HOC extending from the first contact surface to the second contact surface.
[0019] A close coil assembly 130 and an open coil assembly 140 may be positioned on opposing sides of the spool 110, respectively. The close coil assembly 130 may have a contact surface 132 at one side thereof. The first contact surface 110A of the spool may contact the contact surface 132 when the spool 110 moves toward and contacts the close coil assembly 130. The close coil assembly 130 may further have a through hole 134 extending from the contact surface 132 to the opposite side thereof. Similarly, the open coil assembly 140 may have a contact surface 142 at one side thereof. The second contact surface HOB of the spool 110 may contact the contact surface 142 when the spool 110 moves towards and contacts the open coil assembly 140. The open coil assembly 140 may have a through hole 144 extending from the contact surface 142 to the opposite side thereof. A bolt 112 may be arranged through the through holes 134, HOC, 144 for slidably mounting the spool 110 to the control valve body 100. The through holes 134, HOC, 144 may be aligned and have the same diameter.
[0020] FIG. 2 illustrates the relationship of potted winding 150 current to a resultant magnetic field strength. Though the eddy current, and its resultant magnetic field, decay quickly due to resistance losses, there is a time delay in achieving full magnetic field strength without initially overdriving current into a winding 150. FIG. 3 illustrates the location of eddy current in a ferro-magnetic core 152 A and the opposed directions of the primary magnetic field induced by current flowing in the winding 150 and the eddy current magnetic field produced by current flow in the core 152 A.
[0021] FIGS. 4A-B and 5A-B provide more detailed cross sectional views of the open coil assembly 140A-B illustrating modification of the assembly to suppress development of eddy currents in a ferro-magnetic core 152B of an intensifier control valve body 100 when the intensifier control valve body 100 is in use. Eddy currents are generated m electrically conductive elements proximate to time-varying electro-magnetic fields or which are moving with respect to an electro-magnetic field. Electro-magnetic fields are generated in the close coil assembly 130 and open coil assemblies 140A, B.
[0022] The open coil assemblies 140A, B each comprise a potted magnet wire winding 150 on ferro-magnetic cores 152A, B. Ferro-magnetic cores 152A, B may be made of an electrically conductive material. A face from each of ferro-magnetic cores 152A, B is juxtaposed one or the other ends of spool 110. Spool 110 may also be made of an electrically conductive material and is moved by time-varying magnetic fields. Ferromagnetic core 152A, B and spool 110 are positioned closely enough to potted magnet wire winding 150 for eddy currents to be generated in the core and the valve stemming from magnetic flux produced by the winding.
[0023] Modification of the open coil assembly 140B of FIG. 2B as compared to the open coil assembly 140A includes resin filled insulation slots 154 in ferro-magnetic core 152B. Filled insulation slots 154 electrically isolate sub-regions within the ferromagnetic core 152B which in turn localizes any eddy currents which are generated as a consequence of time-varying magnetic flux produced by the winding 150. This isolates eddy currents into smaller regions which can reduce the strength of the reactive, opposing magnetic fields produced by the eddy currents which result in a corresponding reducing the strength of the overall magnetic field operating on the spool 110. The close coil assembly 130 may be similarly modified.
[0024] Filled insulation slots 154 in ferro-magnetic core 152B (and the corresponding core at the opposite end of spool 110) are constructed by machining radial slots from the inside face of the magnetic core to at least the depth of the potted winding 150 and potentially for the full length of ferro-magnetic core 152B. The direction of the insulation slots 154 is generally parallel to the direction of the induced magnetic field. The machined slot is then filled with an electrically insulating material, typically a resin. Generally four filled insulation slots 154 are provided for each of close coil assembly 130 and open coil assembly 140 although more or fewer such slots can be provided, tor however many slots 154 are used, they may conveniently radially oriented and distributed spaced evenly around the core. Here, with four slots 154 being used, a 90 degree spacing between slots is provided moving around the circumference of core 152B. Even spacing of the slots provides predictability, but the mechanism will work without such spacing. FIGS. 6 and 7 isolate and expand on an end view of the ferro-magnetic core 152A-B in order to illustrate the change between cores 152 A (no eddy current suppression) and 152B in greater detail.
[0025] Eddy currents can also be generated near the ends of the spool 110. Eddy currents induced by the primary magnetic field are mitigated somewhat by resultant magnetic fields, however the net field can result in fields being generated by spool eddy currents which oppose the primary field. Spool 110 is modified by incorporation of filled insulated slots 160 introduced from each of end faces 110A, HOB of spool 110. Again the filled insulated slots are radially distributed evenly around the spool. Spool 110 is shown with four such insulated slots 160. The insulated slots break up the ends of the spool 110 into mutually isolated regions in which eddy currents develop.
[0026] The elongated, filled, electrically insulating slots disposed in spool 110 and cores 152A-B function as interstitial boundaries within the spool and cores and reduce the volume of material in which eddy currents circulate and thereby limit or suppress their development. This reduces the strength and duration of the resultant magnetic fields produced by the eddy currents.
[0027] Valve body 100 operation should be quicker and more consistent with suppression of eddy currents. The ill effects of cold start operation, dirty oil operation and worn injector operation can also be mitigated.

Claims

What is claimed is:
1. A control valve comprising: a main body; a close coil assembly located on a first side of the main body and having a contact surface; an open coil assembly located on a second side of the main body and having a contact surface; a spool arranged in the main body and configured to move between the contact surfaces; the close and open coil assemblies comprising first and second electrically conductive ferro-magnetic cores with first and second wire coils wound thereon, respectively, the first and second electrically conductive ferro-magnetic coils having a longitudinal dimension with a plurality of electrically insulated slots parallel thereto.
2. The control valve of claim 1, further comprising: the spool including at each of two ends proximate the contact surfaces, a plurality of longitudinal insulated slots arranged radially around a central axis of the spool and extending inward longitudinally from the ends of the spool.
3. An intensifier control valve assembly for an engine fuel injection system, the intensifier control valve assembly comprising: a main body; a close coil assembly located on a first side of the main body and having a contact surface; an open coil assembly located on a second side of the main body and having a contact surface; a spool arranged in the main body and configured to move between the contact surfaces; the close and open coil assemblies comprising first and second electrically conductive ferro-magnetic cores, the electrically conductive ferro-magnetic cores including interstitial insulating boundaries for isolating regions in which eddy currents can occur.
4. The intensifier control valve assembly of claim 3, further comprising: the spool being made of an electrically conductive material and including interstitial insulating boundaries for isolating regions in which eddy currents can occur.
5. The intensifier control valve assembly of claim 4, further comprising the interstitial insulating boundaries in the spool being radially disposed with respect to the direction of elongation of the spool and extending longitudinally inwardly from opposite ends of the spool.
6. The intensifier control valve of claim 4, further comprising the interstitial insulating boundaries of the electrically conductive ferro-magnetic cores being radially arranged with respect to axes of the coil assemblies.
PCT/US2012/041558 2011-09-02 2012-06-08 Low eddy current intensifier control valve WO2013032554A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161530502P 2011-09-02 2011-09-02
US61/530,502 2011-09-02

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Citations (6)

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US6124775A (en) * 1997-03-05 2000-09-26 Kelsey-Hayes Company Bobbinless solenoid coil
US20030006298A1 (en) * 2001-07-06 2003-01-09 Jens Gebhardt Control valve body for an oil activated fuel injector
US6653921B2 (en) * 2001-09-21 2003-11-25 Denso Corporation Magnetic member for electromagnetic driving device and manufacturing method thereof
US6798636B2 (en) * 2000-11-14 2004-09-28 Magneti Marelli Powertrain S.P.A. Method of estimating the effect of the parasitic currents in an electromagnetic actuator for the control of an engine valve
US20090139490A1 (en) * 2007-12-03 2009-06-04 Continental Automotive System Us, Inc. Control method for closed loop operation with adaptive wave form of an engine fuel injector oil or fuel control valve

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4340829A (en) * 1979-06-22 1982-07-20 Sheller Globe Corporation Molded end coil insulator
US6124775A (en) * 1997-03-05 2000-09-26 Kelsey-Hayes Company Bobbinless solenoid coil
US6798636B2 (en) * 2000-11-14 2004-09-28 Magneti Marelli Powertrain S.P.A. Method of estimating the effect of the parasitic currents in an electromagnetic actuator for the control of an engine valve
US20030006298A1 (en) * 2001-07-06 2003-01-09 Jens Gebhardt Control valve body for an oil activated fuel injector
US6653921B2 (en) * 2001-09-21 2003-11-25 Denso Corporation Magnetic member for electromagnetic driving device and manufacturing method thereof
US20090139490A1 (en) * 2007-12-03 2009-06-04 Continental Automotive System Us, Inc. Control method for closed loop operation with adaptive wave form of an engine fuel injector oil or fuel control valve

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