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AS 1246 Push and Pull Solenoid with Long stroke Feature for automation equipment

Part 1: Long Stroke Solenoid Working Principle

The long-stroke solenoid is mainly composed of a coil, a moving iron core, a static iron core, a power controller, etc. Its working principle is as follows

1.1 Generate suction based on electromagnetic induction: When the coil is energized, the current passes through the coil wound on the iron core. According to Ampere's law and Faraday's law of electromagnetic induction, a strong magnetic field will be generated inside and around the coil.

1.2 The moving iron core and the static iron core are attracted: Under the action of the magnetic field, the iron core is magnetized, and the moving iron core and the static iron core become two magnets with opposite polarities, generating electromagnetic suction. When the electromagnetic suction force is greater than the reaction force or other resistance of the spring, the moving iron core begins to move toward the static iron core.

1.3 To achieve linear reciprocating motion: The long-stroke solenoid uses the leakage flux principle of the spiral tube to enable the moving iron core and the static iron core to be attracted over a long distance, driving the traction rod or push rod and other components to achieve linear reciprocating motion, thereby pushing or pulling the external load.

1.4 Control method and energy-saving principle: The power supply plus electric control conversion method is adopted, and the high-power start-up is used to enable the solenoid to quickly generate sufficient suction force. After the moving iron core is attracted, it is switched to low power to maintain, which not only ensures the normal operation of the solenoid, but also reduces energy consumption and improves work efficiency.

Part 2 : The main characteristics of the long-stroke solenoid are as follows:

2.1: Long stroke: This is a significant feature. Compared with ordinary DC solenoids, it can provide a longer working stroke and can meet the operation scenarios with higher distance requirements. For example, in some automated production equipment, it is very suitable when objects need to be pushed or pulled for a long distance.

2.2: Strong force: It has sufficient thrust and pulling force, and can drive heavier objects to move linearly, so it can be widely used in the drive system of mechanical devices.

2.3: Fast response speed: It can start in a short time, make the iron core move, quickly convert electrical energy into mechanical energy, and effectively improve the working efficiency of the equipment.

2.4: Adjustability: The thrust, pull and travel speed can be adjusted by changing the current, number of coil turns and other parameters to adapt to different working requirements.

2.5: Simple and compact structure: The overall structural design is relatively reasonable, occupies a small space, and is easy to install inside various equipment and instruments, which is conducive to the miniaturization design of the equipment.

Part 3 : The differences between long-stroke solenoids and comment solenoids :

3.1: Stroke

Long-stroke push-pull solenoids have a longer working stroke and can push or pull objects over a long distance. They are usually used in occasions with high distance requirements.

3.2 Ordinary solenoids have a shorter stroke and are mainly used to produce adsorption within a smaller distance range.

3.3 Functional use

Long-stroke push-pull solenoids focus on realizing the linear push-pull action of objects, such as being used to push materials in automation equipment.

Ordinary solenoids are mainly used to adsorb ferromagnetic materials, such as common solenoidic cranes that use solenoids to absorb steel, or for adsorption and locking of door locks.

3.4: Strength characteristics

The thrust and pull of long-stroke push-pull solenoids are relatively more concerned. They are designed to effectively drive objects in a longer stroke.

Ordinary solenoids mainly consider the adsorption force, and the magnitude of the adsorption force depends on factors such as the magnetic field strength.

Part 4 : The working efficiency of long-stroke solenoids is affected by the following factors:

4.1 : Power supply factors

Voltage stability: Stable and appropriate voltage can ensure the normal operation of the solenoid. Excessive voltage fluctuations can easily make the working state unstable and affect efficiency.

4.2 Current size: The current size is directly related to the strength of the magnetic field generated by the solenoid, which in turn affects its thrust, pull and movement speed. The appropriate current helps to improve efficiency.

4.3 : Coil related

Coil turns: Different turns will change the magnetic field strength. A reasonable number of turns can optimize the performance of the solenoid and make it more efficient in long-stroke work. Coil material: High-quality conductive materials can reduce resistance, reduce power loss, and help improve work efficiency.

4.4: Core situation

Core material: Selecting a core material with good magnetic conductivity can enhance the magnetic field and improve the working effect of the solenoid.

Core shape and size: The appropriate shape and size help to evenly distribute the magnetic field and improve efficiency.

4.5: Working environment

- Temperature: Too high or too low temperature may affect the coil resistance, core magnetic conductivity, etc., and thus change the efficiency.

- Humidity: High humidity may cause problems such as short circuits, affect the normal operation of the solenoid, and reduce efficiency.

4.6 : Load conditions

- Load weight: Too heavy a load will slow down the solenoid's movement, increase energy consumption, and reduce work efficiency; only a suitable load can ensure efficient operation.

- Load movement resistance: If the movement resistance is large, the solenoid needs to consume more energy to overcome it, which will also affect efficiency.

product details

Product Description

Brand	Dr. Solenoid	Model Number	AS 1246
Rated Voltage (V)	DC 6V，12V or 24V	Rated Power(W)	20--25 W
Work Mode	Push and Pull	Holding Force (N)	1000---12000 GF
Stroke(mm)	20--30 MM Customized	Reset Time(s)	1 S On，9 S OFF
Service Life	200 Thousand Times	Certification	CE,ROHS,ISO9001,
Material	Superior Magnet Iron	Lead Wire Length(mm)	200 MM
Install Style	Screw	Tolerance of Dimension	+/- 0.1 MM
Water-proof	None	Insulation Class	B
Hi-Pot Test	AC 600V 50/60Hz 2s	Non-excitation Holding Force	0
Working Temperature	-10°C-100°C	Duty Cycle	1-100%
Thread Depth(mm)	/	Payment Term	TT, or LC At Sight
Sample Order	Yes	Warranty	1 Year
MOQ	1000 pcs	Supply Ability	5000 pcs per Week
Delivery Time	30 Days	Port of Loading	shenzhen

Part 1 ： Long-stroke solenoids have many application scenarios:

1.1 Industrial automation field

- Material handling and transportation: In the conveyor belt system of an automated production line, a long-stroke solenoid can push products from one conveyor belt to another, or move products to a designated processing station. The long-stroke characteristics can meet the needs of material transfer over a large distance.

1.2： Robotic arm motion control: used to control the extension and contraction of the robot arm, to achieve the grasping and placement of target objects at different positions, so that the robot arm can operate flexibly within a larger working range.

1.3： Automobile manufacturing and maintenance

- Automobile assembly production line: During the assembly process of automobile parts, the parts can be accurately pushed to the installation position, such as the positioning when installing automobile seats, dashboards and other components.

- Automobile testing equipment: On the automobile testing line, the detection probe is driven to move to detect various parts of the car. For example, when detecting the chassis of the car, the long-stroke solenoid can enable the detection equipment to flexibly penetrate into various positions at the bottom of the chassis.

1.4： Electronic equipment production

- Circuit board testing: In the circuit board automated testing equipment, the long-stroke solenoid can be used to move the test probe so that it can contact the test points at different positions on the circuit board to complete complex circuit testing work.

1.5： Logistics warehousing

- Storage shelf operation: In the automated stereoscopic warehouse, it is used to drive the pallet of the shelf to move, which is convenient for the storage and extraction of goods. The advantage of the long stroke can realize the efficient transfer of goods between different layers of the shelf.

Part 2 ： When designing a long-stroke solenoid, the following factors need to be considered:

2.1 ：Magnetic field and solenoidic force

- Magnetic field strength requirements: Design the magnetic field strength according to the required thrust or pull. This involves reasonably determining the number of coil turns and the current size to generate a strong enough magnetic field so that the moving iron core can work effectively in a long stroke.

2.2： solenoidic force calculation: Accurately calculate the solenoidic force through theoretical formulas to ensure that the solenoid can overcome the load resistance throughout the stroke. The solenoidic force should consider the impact of stroke changes on the magnetic field distribution and strength.

2.3： Core design

- Core material selection: Select core materials with high magnetic permeability and low coercivity, such as pure iron, silicon steel sheets, etc., to enhance the magnetic field and reduce hysteresis losses. Good core materials can improve the efficiency and performance of the solenoid.

2.4： Core shape and size: Design a suitable core shape, such as a cylindrical or T-shaped, to ensure that the magnetic field is evenly distributed and can effectively guide the magnetic flux to meet the requirements of long strokes. The size design should consider the matching of the core and the coil, as well as the stability under long strokes.

Part three ：The frequency questions often occur in long-stroke Solenoid:

3.1 : Insufficient suction

3.1.1 Cause: The power supply voltage may be too low, resulting in a small current passing through the coil and a weak magnetic field; the number of coil turns may be reduced due to damage, affecting the magnetic field strength; or the core may be aged or rusted, causing the magnetic conductivity to deteriorate.

3.1.2 Performance: Unable to pull or push the load normally, slow movement or inability to complete the movement.

3.2 : Insufficient stroke

- Cause: Wear or deformation of mechanical parts, such as bending of the push rod, limiting the stroke length; or displacement of the internal structure of the electromagnet, resulting in the working stroke not meeting the design requirements.

- Performance: The object cannot be pushed to the specified position or pulled back a sufficient distance.

3.3: Severe heating

- Cause: First, long-term continuous work, the coil resistance heats up; second, the short circuit between the coil turns causes the current to increase abnormally, thereby generating too much heat; third, the working environment temperature is too high, and poor heat dissipation will also aggravate the heating.

- Performance: If the temperature of the electromagnet is too high, it will not only affect its performance, but also damage the insulating material and cause failures.

3.4: Slow response

- Cause: It may be a problem with the control circuit, such as signal transmission delay; or the iron core is heavy and the friction is large, resulting in slow start and stop of the action.

- Symptom: In application scenarios that require fast response, the push and pull actions cannot be completed in time.