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Case Study 1:  Fatigue improvement - Bearing with twin-communication grooves in stators

With the car increasing the mileage, the dirt will flow in the oil, especially the plunger of control elements - solenoid valves
occurs the "stick" condition, so that the electromagnetic valve failure. In addition, the fluid in the solenoid valve doesn't have
enough oil circulation or convection so that the oil temperature rises too quickly.

The original design of this case show as follows:
When the dirt is gradually accumulated, it is possible to have the stick condition between the plunger and bearings. It must have communication holes near bearings. In this case, this fluid communication path is 1 -> 2 -> stop. The fluid cannot flow from 2 to 3 resulting in the oil temperature rising and lack of enough convection. Also insufficient thickness of the upper stator results in no communication holes in the upper stator.


The upper stator uses three parts and cost higher than the target price.
The lower stator uses three parts and cost higher than the target price.
The known problem:
Based on this analysis, and the situation that the performance cannot be reduced, SINS uses some methods to achieve
this target.
First of all, SINS uses a special bearing with twin-communication grooves to communicate the fluid path: 1-> 2 -> 3 -> circulation. In addition, the original part-2 are all canceled. The special bearings were setup in the stators directly. Of course, the magnetic performance needs to consider first. When the magnetic performance is the same as original, SINS' design adds on the feature - lower and stable oil temperature and can accommodate much more dirt than the original.

Only use two parts to result in the better performance.
Only use two parts to result in the better performance.
Conclusion:
The known problem - oil temperature, dirt, cost, number of parts were solved by using this special part - bearing with communication holes
and software magnetic simulation to change the dimensions. The fatigue life of this solenoid have been increased lots by this improvement.

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