The Ultimate Guide to Understanding and Fixing DC Solenoid and Electromagnet Failures

Part 1 : Power failure

Problem description: Insufficient or interrupted power supply is a common cause of DC solenoid failure. For example, a dead battery, a damaged power adapter, or a loose electric wire connection may prevent the electromagnet from obtaining enough power to generate a magnetic field.

Solution: Use a voltmeter to check the power supply output and make sure it is within the voltage range required by the DC solenoid. If it is battery-powered, replace it with a new one; if it is a power adapter problem, consider replacing it with a suitable one. For loose circuit connections, carefully check and reconnect the wires to ensure the connection is secure.

Part 2 : Unstable voltage

Problem description: Voltage fluctuations may affect the performance of the DC solenoid. When the voltage is lower than the rated value, the magnetic field strength generated by the electromagnet will be weakened; and too high a voltage may damage the windings of the DC solenoid.

Solution: Install a voltage regulator to stabilize the input voltage and ensure that it remains within the operating voltage range designed for the electromagnet.

Part 3 : Winding short circuit

Problem description: If the winding of the DC Solenoid is short-circuited, the current will bypass part of the winding, causing the magnetic field to weaken or disappear completely. This may be caused by the insulation layer of the winding being damaged, causing the wires to touch each other.

Solution: Use an insulation resistance meter to check the insulation resistance of the winding and determine the short circuit location. If the short circuit is small, you can try to repair the insulation layer; if the short circuit is serious, you may need to rewind the winding.

Part 4 :  Winding break

Problem description: The wire break in the winding will prevent the current from passing, causing the DC Solenoid to fail. This may be caused by long-term operation causing the wire to age, overstretch, or mechanical damage.

Solution: Use the resistance range of the multimeter to check whether the winding is broken. If a break is found, try to find the breakpoint and weld it to repair it. If the breakpoint cannot be found or the winding is severely damaged, the winding needs to be replaced.

Part 5 : Plunger wear or damage

Problem description: The plunger is a key component to enhance the magnetic field of the DC solenoid. If the surface of the plunger is severely worn or cracked, it will affect the conduction and concentration of the magnetic field, thereby reducing the performance of the electromagnet.

Solution: Check the appearance of the plunger. For minor wear, it can be polished and repaired; if cracks or severe damage occur, the plunger should be replaced.

Part 6 : Core magnetization saturation

Problem description: When the current passing through the DC solenoid is too large or the magnetic permeability of the plunger material reaches the limit, the plunger will be magnetized and saturated. At this time, even if the current is increased, the magnetic field strength will not increase significantly, and it may even cause the electromagnet to heat up seriously.

Solution: According to the design requirements of the electromagnet, reasonably control the current size. If the magnetic saturation is caused by inappropriate core material, you can consider replacing the core material with a higher magnetic permeability limit.

Part 7 : Environmental issues

Temperature is too high or too low.

Problem description: Extreme temperature will affect the performance of the electromagnet. High temperature may increase the resistance of the winding, age the insulation material, and even make the core lose its magnetism; low temperature may make the material brittle and affect the mechanical properties.

Solution: For high temperature environments, heat dissipation devices such as heat sinks or fans can be installed to help the electromagnet dissipate heat. In low temperature environments, try to use cold-resistant materials to make electromagnets, or properly insulate the electromagnets.

Part 8 : Humid or corrosive environment

Problem description: In a humid environment, moisture may penetrate into the electromagnet, causing the winding to short-circuit or the core to rust. In a corrosive environment, chemicals can corrode the electromagnet's components, damaging the insulation and core.

Solution: Seal the electromagnet to prevent moisture and corrosive gases from entering. If the electromagnet has been corroded, use a suitable cleaner to remove the corrosion, then repair or replace the damaged parts and take protective measures, such as applying anti-corrosion paint.

Part 9  Summary:

The reasons why the electromagnet fails to work are the above common problems, but there are some other practical issue, which need to be analyzed according to the actual situation or the sample. We are a solenoid and solenoid valve manufacturer specializing in design, verification and production of electromagnets and solenoid valves. In actual product operation, we will provide customers with relevant suggestions to optimize related products and structures according to the customer's specifications and our past 17 years of production and design experience. If you encounter related problems in the production or design of electromagnets and solenoid valves, you are also welcome to send us emails for consultation and contact us.