Solenoid Manufacturers

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About Solenoids

A solenoid is a type of electromagnet. It is made up of a wire loop that is wound around a core. When current passes through it, a magnetic field is produced. The magnetic field that is produced is uniform and can be used to control other magnetic fields. Solenoids convert energy from one form to another hence they are also a type of actuators. Solenoids are available for AC and DC current.

Solenoids give repeatable and predictive performance and have a life of 100 million cycles. They need very little control since they are pulse devices. The response time is in milliseconds (ms) and is smooth.

Applications of Solenoids

Solenoids have varied uses. Rotary solenoids are used in High Speed Food making, equipment for Laser Etching, Medical Imaging, controls for Medical Laser, Medical Ventilation, Paper making and handing, Robotics, controlling valves, equipment for high speed video inspection, pinch rollers and many others.

Linear solenoids are Banking Industry, Beverage dispensers, blood analysis equipment, electronic cash registers, circuit breakers, agriculture and farming equipment, food packing and processing machinery, Electric Door Locks, Pharmaceutical Dispensers, Printing Equipment, Security Systems, vending machines, medical transfusion and sterilization, data storage and retrieval systems, Braille printers, card readers and many more.

MIL-Spec solenoids can operate at high altitudes and pressures and their operating temperature is -65 to +125°C. They are used in defense and commercial airplanes for air, hydraulic and fuel valve actuators, engine throttle control pressure door locking, hatch and fin moving mechanisms, bomb and missile racks, thrust reversing interlocks and many other applications like missile systems where the shock loads are tremendous.

How Solenoids work

A solenoid has a coil made of conducting wires, a frame and a plunger. The coil has many turns of copper wire that is tightly wound. When current flows in the wire, a strong magnetic flux is created and it flows through and around the coil. The frame is made of tubular steel or iron case that strengthens the magnetic field.

The plunger is cylindrical with a round cross section and it has a positive cone a one end. When he plunger is placed in the coil center, the magnetic filed increases. The cone fits into the negative cone at the frame bottom and this provides a larger area to transfer the flux. When he coil is energized, the plunger moves into the coil. Push type of plungers is made by fixing a pushpin at the plunger's cone and a pull type is made by attaching a hook at the outer end.

Solenoids use electromechanical energy or derive their energy from pneumatic or hydraulic pressure.

Maximum stroke is the amount of distance the plunger travels in a stroke. Response time is the time taken to move the plunger through its stroke without any load. Compression or return springs are used to retain the plunger when the solenoid is not given power.

Types of Solenoids

Types of solenoids are: Continuous duty linear solenoids, intermittent duty linear solenoids, Rotary solenoids continuous duty, Rotary Solenoids Intermittent Duty. Linear types move the plunger in a forward and backward direction while rotary solenoids rotate the plunger. They are briefly explained as below:

• Frame Solenoids: These solenoids have different types of frames to house the plunger and windings. Tube frames are used for solenoids that have long strokes. C-frame are often used for solenoids used in power management devices, security applications, medical instrumentation and others. D-frame (also called box-frame) solenoids are used in office equipment, portable business machines and for small business machines. Open frame type of solenoids is economical and used in electro mechanical applications.
• Electro Mechanical Solenoids: These types of solenoids have a coil that is electromagnetic and inductive, paced around a armature. The armature is movable and made of steel or iron. The armature can move inside the coil. When electric current is passed through the coil, the coils inductance is changed and it becomes an electromagnet. When the force applied to the armature to make it move is increased, the coils inductance is also increased. Alternately the armature moves in a direction that increases the inductance.
• Pneumatic Solenoids: These are very commonly used as actuating mechanisms in machine tools and CNC machine tools for tool clamp de-clamp and table rotation. It works like the piston of automobiles. The solenoid is made of a thin walled metal tube and the ends have intake and exhaust ports. A rod connects the actuator with the piston. When pressure is applied to one end of the piston, it exerts a lot of pressure and this is released from the other end. For reverse direction pressure, pressure is applied from the other end. The solenoid amplifies small pressures and can generate very high amount of pressure with smaller input pressures. Greater the tube diameter, larger is the pressure that is developed.
• Hydraulic Solenoids: Hydraulic solenoids work on the same principle as the pneumatic solenoid. Pressure is exerted by the hydraulic fluid in the hydraulic lines. The amount of pressure generated is much higher than other systems and these types of solenoids are used in hydraulic brake systems and in press machines.
• Linear Solenoids Continuous Duty: These are rated for continuous cycle and can remain in the on state for up to 30 minutes, retaining the high pressure. They are used to convert electrical into mechanical energy. The device has a plunger that is controlled by electrical windings. The plunger moves forward and backward and has a maximum stroke length or the distance it can travel. The coil winding reduces current drain and allows heat to be dissipated. Initially, in the un-powered state, the plunger is in its extended position. When current is passed, the plunger is moved to its seated position. A backstop, pole piece is used for support. When the electric current is stopped, the plunger is pulled back into its extended position. Sometimes two coils are used since they provide a weaker push and pull force on the plunger. They can provide 30 psi force with a small unit about 2 1/4" long.
• Linear Solenoids Intermittent Duty: These devices convert electrical energy to mechanical power by pushing or pulling a plunger. They are used for on and off applications for a cycle that is less than 100%. The coil is housed in a frame of different shapes. When current is passed, he plunger is pulled from its extended position to the seated powered position. Suitable backstops are used for support. These types of solenoids are smaller than continuous duty solenoids and they have high pull strength and hold strength.
• Rotary Solenoids Continuous Duty: Rotary solenoids have similar design as the linear solenoids and are meant for 100 % duty cycles. Linear motion of the plunger that is moved by the magnetic field from the windings is converted into rotary motion with three tiny ball bearings. The ball bearings are placed on a inclined plane. As the plunger moves by a tiny amount, the axial stroke is converted into rotary. In some rotary solenoids, the magnetic coils are arranged in such a manner that the pin movement is directly turned into rotary. These devices generate a lot of heat when used for continuous duty rating. They can develop more than 100 psi torque from a small unit about 2 1/4" long.
• Rotary Solenoids Intermittent Duty: These devices are rated for less than 100% continuous duty cycle and cannot hold the plunger in position if the time is exceeded. Electricity is passed through a tightly wound coil and a magnetic field is generated. By using an iron frame, the permeability increases and the magnetic flux also rises. A plunger and inclined ball bearing system is laced in the coils. When the plunger is displaced linearly, the motion is converted to rotary by the ball bearings.
• Variable Positioning Solenoids: The stop positions for the plunger can be varied by using sliders. This increases the capacity of the solenoid and they are used in devices like brush less torque actuators.

Considerations for Solenoids

An unambiguous understanding of your requirements will greatly help you choose which kind of solenoid is best for the situation. Consider the following factors when choosing solenoids:

• Solenoids produce high force when they work on intermittent bursts. With continuous type, the holding force is weaker.
• 'Jumping' the solenoid by increasing the rated input voltage for more performance should be strongly discouraged. With constant use, the coil temperature rises to dangerous levels and the load can be jettisoned or the coil can burn out.
• Plungers tend to stick and remain jammed even when the process ends. In such cases, the solenoid should be disconnected and opened by trained personnel and repaired or cleaned. An attempt to use a nail to push back the pin is very dangerous.
• For corrosive or abrasive environments use solenoids with plunger seals.

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