Solenoid Frame Types : which one is right for your project ?
Content :
Part 1 : what is DC Frame Solenoid
Part 2 : Frame type solenoid Structure
Part 3: DC Frame Solenoid Working Principle
Part 4 : What are the common types of frame type solenoids?
Part 6 : How to select the appropriate frame type solenoid?
Part 7 : The advantage and disadvantage of frame type solenoid
Part 8 : How to select the appropriate frame type solenoid for your project need ?
Part 9: Are there any specific precautions for using frame type solenoids?
Part 10 : Summery
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Part 1 : What is A DC frame solenoid ?
A DC frame solenoids, it is also known as a DC push-pull solenoid or electromagnet. It is a simple structure, cost-effective linear motion solenoid that built in a coil of copper wire wound around a centre iron core to create a magnetic field , which then pushes or pulls a plunger when energized.
Part 2 : Frame type solenoid Structure
2.1 Solenoid Coil: Usually made of copper wire, which has excellent electrical conductivity. When an electric current passes through the coil, a magnetic field is generated around it.
2.2 Frame Housing: Typically constructed of a ferromagnetic material such as soft iron. The frame can enhance the magnetic field generated by the coil. In a C - frame solenoid, the frame is in the shape of the letter "C" and covers the coil on one side. In a D - frame solenoid, the frame consists of two pieces that cover the coil on two sides.
2.3 Movable Plunger: Made of a ferromagnetic material. It is placed inside the frame and will be attracted to the center of the coil when the solenoid is energized, causing it to move.
Part 3 : Working Principle
When an electric current is applied to the solenoid coil of the frame type solenoid, it induces a magnetic field in the solenoid coil. The interaction between this magnetic field and the ferromagnetic frame creates a strong, localized magnetic field. The movable plunger is then attracted by the magnetic field and moves towards the center of the coil. This movement can be utilized to perform mechanical work, such as opening or closing a valve, moving a lever, or pushing a button. The strength of the magnetic field, and thus the force exerted on the plunger, can be controlled by varying the electric current supplied to the coil.
Part 4 : What are the common types of frame type solenoids?
Common types of frame type solenoids mainly include DC C-frame solenoids and DC O-frame solenoids. The specific introduction is as follows:
4.1 DC C-Frame Solenoids
Structure: It features a C-shaped frame that wraps around the wire coil. This structure provides a certain magnetic circuit path and space for the coil, which helps to concentrate the magnetic field and improve the utilization efficiency of the magnetic field.
Features: It uses a stroke operation with more control, enabling accurate control of the movement of the core and the generated magnetic force. It can work stably in a DC power supply environment and has good adaptability to different loads and working conditions.
Applications: It is suitable for many daily applications, such as circuit breakers, camera shutters, scanners, coin counters, and gaming machines.
4.2 DC O-Frame Solenoids
Structure: The O-shaped frame is made of two joined pieces that shield the coil. This structure provides better protection and magnetic field confinement for the coil, reducing the influence of external factors on the magnetic field and improving the stability and reliability of the solenoid.
Features: It also has the characteristic of stroke operation control and can work under both DC and AC power supplies. It has a relatively high electromagnetic conversion efficiency and can output a relatively stable magnetic force.
Part 5 ； Frame type Solenoid Applications: It is often used in ATM machines, gaming machines, and gas- and blood-analyzing equipment.
In addition, from the perspective of power supply type, frame type solenoids can also be divided into AC frame type solenoids and DC frame type solenoids. AC frame type solenoids are suitable for occasions with alternating current power supply, and have the characteristics of large starting force and high working efficiency; DC frame type solenoids are suitable for occasions that require stable magnetic force output and precise control, and have better stability and controllability.
Part 6 : How to select the appropriate frame type solenoid?
When selecting an appropriate frame type solenoid, the following aspects need to be considered:
Installation Dimensions
6.1 Overall Size: Measure the available space in the equipment where the solenoid will be installed. Ensure that the length, width, and height of the frame type solenoid fit within the designated area. For example, in a compact electronic device, a solenoid with dimensions of 20mm×30mm×40mm might be suitable, while in a larger industrial machine, a larger solenoid can be accommodated.
6.2 Mounting Holes and Slots: Check the position and size of the mounting holes or slots on the solenoid and make sure they match the corresponding structures on the equipment. This ensures a secure and proper installation.
6.3 Electrical Parameters
Power Supply Type: Determine whether the application requires an AC or DC power supply. AC solenoids are often used in some industrial equipment connected to the mains power, while DC solenoids are more common in battery-powered devices or systems with stable DC power sources.
6.4 : Voltage Rating: Select a solenoid with a rated voltage that matches the available power supply. Common voltages include DC 12V, 24V, and AC 220V. Using a solenoid with the wrong voltage can lead to improper operation or even damage.
Current and Power Consumption: Consider the current and power consumption of the solenoid based on the power supply capacity and the overall power budget of the system. This is especially important in systems with multiple components to avoid overloading the power supply.
6.5 : Force and Stroke Requirements
Required Force: Calculate the force needed to perform the specific task, such as pushing, pulling, or holding an object. Solenoids are typically rated in terms of their pulling or pushing force, usually in Newtons. For example, if a solenoid is used to open a valve, it needs to have enough force to overcome the resistance of the valve mechanism.
Stroke Length: Determine the required stroke length, which is the distance the solenoid's core needs to move. This depends on the specific application. For instance, in a door lock mechanism, the stroke might only need to be a few millimeters to engage or disengage the lock.
6.6 Operating Mode and Duty Cycle
Continuous or Intermittent Operation: Decide whether the solenoid will operate continuously or intermittently. Continuous operation requires a solenoid that can handle heat dissipation and wear over long periods, while intermittent operation allows for a more flexible selection based on the on-off cycle.
6.7 Duty Cycle: The duty cycle is the ratio of the on-time to the total cycle time. If a solenoid has a high duty cycle, it needs to be able to handle the heat generated during extended periods of operation. For example, a solenoid with a 50% duty cycle means it is on for half of the time and off for the other half.
6.7 Environmental Conditions
Temperature: If the solenoid will be used in a high-temperature environment, such as in a furnace or near an engine, choose a solenoid with a high-temperature resistance rating. In cold environments, ensure that the solenoid can still operate properly without issues like reduced magnetic force.
6.8 Humidity and Moisture: In humid or wet environments, a solenoid with waterproof or moisture-resistant properties is required to prevent corrosion and short circuits.
Dust and Chemicals: In dusty or chemically corrosive environments, select a solenoid with appropriate protection, such as a sealed enclosure, to prevent dust or chemicals from entering and affecting its performance.
6.9 Response Time and Precision
Response Time: For applications that require quick action, such as in high-speed machinery or rapid switching systems, choose a solenoid with a short response time. This ensures that the solenoid can activate and deactivate quickly as needed.
Precision: If the solenoid needs to provide precise positioning or force control, look for solenoids with high precision and stability. This is often crucial in applications like robotics and precision manufacturing.
6.9 Brand and Reputation: Choose solenoids from well-known and reputable brands that have a track record of producing high-quality products. This can increase the reliability and lifespan of the solenoid.
Certifications and Standards: Check if the solenoid meets relevant industry standards and certifications, such as UL, CE, etc. This ensures that the solenoid complies with safety and performance requirements.
6.10 Cost and Budget
Initial Cost: Consider the purchase cost of the solenoid. While it may be tempting to choose the cheapest option, it's important to balance cost with performance and quality to avoid costly replacements or maintenance in the future.
Long-Term Costs: Take into account the long-term costs, including power consumption, maintenance, and potential replacement costs. A higher-quality solenoid with lower power consumption and better reliability may be more cost-effective in the long run.
Part 7 : The advantage and disadvantage of frame type solenoid
Frame type solenoids, also known as box type solenoids, have both advantages and disadvantages. The details are as follows:
7.1 Advantages Compact Design
Frame type solenoids have a compact structure with a reasonable layout of coils and cores in a limited space. This makes them easy to install in equipment with space constraints, offering great convenience for equipment miniaturization and integration.
Good Heat Dissipation Performance
The coil part of frame type solenoids is open, which provides good air circulation and heat dissipation. This effectively reduces temperature rise during long-term use, prolongs the service life of the solenoid, and reduces the risk of performance degradation and malfunctions caused by overheating.
7.2 High Magnetic Force and Long Stroke
By using high-permeability materials and a conical matching magnetic circuit structure, frame type solenoids can provide a large stroke and attractive force with a relatively small volume and weight, meeting the requirements of applications that require high power and long stroke.
7.3 Rapid Response
Frame type solenoids have a very rapid interaction between the magnetic field and the armature. They can quickly generate magnetic force to move the core when energized, and the magnetic force can quickly disappear when power is cut off. This enables them to adapt to high-speed movement and fast switching requirements, improving the operational efficiency and accuracy of the equipment.
7.4 Precise Control
The attractive force, repulsive force and the movement state of the core of frame type solenoids can be accurately controlled by adjusting the magnitude and direction of the input current. This makes them ideal for applications that require high-precision position and speed control, such as in industrial automation and medical equipment.
7.5 Disadvantages
Limited Magnetic Field Uniformity
Due to their structural characteristics, the magnetic field distribution of frame type solenoids may not be very uniform, which may lead to uneven force on the armature in some cases, affecting the stability and accuracy of the movement.
7.6 Sensitive to Installation Accuracy
Frame type solenoids are relatively sensitive to installation accuracy. Improper installation, such as uneven gaps between the core and the coil or misalignment, can affect their normal operation, resulting in problems such as reduced suction and increased noise.
7.7 Electromagnetic Interference
When frame type solenoids are in operation, they may generate electromagnetic interference, which can affect the normal operation of surrounding electronic devices and circuits. In some cases, additional shielding and anti-interference measures are required.
7.8 High Cost
The manufacturing process of frame type solenoids is relatively complex, requiring high-precision processing and assembly technology. In addition, the materials used are often of high quality, which leads to a relatively high cost compared to some other types of solenoids. This may increase the overall cost of the equipment in some applications.
Part 8 : How to select the appropriate frame type solenoid?
When selecting an appropriate frame type solenoid, the following aspects need to be considered:
8.1 Installation Dimensions
Overall Size: Measure the available space in the equipment where the solenoid will be installed. Ensure that the length, width, and height of the frame type solenoid fit within the designated area. For example, in a compact electronic device, a solenoid with dimensions of 20mm×30mm×40mm might be suitable, while in a larger industrial machine, a larger solenoid can be accommodated.
Mounting Holes and Slots: Check the position and size of the mounting holes or slots on the solenoid and make sure they match the corresponding structures on the equipment. This ensures a secure and proper installation.
8.2 Electrical Parameters
Power Supply Type: Determine whether the application requires an AC or DC power supply. AC solenoids are often used in some industrial equipment connected to the mains power, while DC solenoids are more common in battery-powered devices or systems with stable DC power sources.
8.3 Voltage Rating: Select a solenoid with a rated voltage that matches the available power supply. Common voltages include DC 12V, 24V, and AC 220V. Using a solenoid with the wrong voltage can lead to improper operation or even damage.
8.4 Current and Power Consumption: Consider the current and power consumption of the solenoid based on the power supply capacity and the overall power budget of the system. This is especially important in systems with multiple components to avoid overloading the power supply.
8.5 Force and Stroke Requirements
Required Force: Calculate the force needed to perform the specific task, such as pushing, pulling, or holding an object. Solenoids are typically rated in terms of their pulling or pushing force, usually in Newtons. For example, if a solenoid is used to open a valve, it needs to have enough force to overcome the resistance of the valve mechanism.
Stroke Length: Determine the required stroke length, which is the distance the solenoid's core needs to move. This depends on the specific application. For instance, in a door lock mechanism, the stroke might only need to be a few millimeters to engage or disengage the lock.
8.6 Operating Mode and Duty Cycle
Continuous or Intermittent Operation: Decide whether the solenoid will operate continuously or intermittently. Continuous operation requires a solenoid that can handle heat dissipation and wear over long periods, while intermittent operation allows for a more flexible selection based on the on-off cycle.
8.7 Duty Cycle: The duty cycle is the ratio of the on-time to the total cycle time. If a solenoid has a high duty cycle, it needs to be able to handle the heat generated during extended periods of operation. For example, a solenoid with a 50% duty cycle means it is on for half of the time and off for the other half.
8.8 Environmental Conditions
Temperature: If the solenoid will be used in a high-temperature environment, such as in a furnace or near an engine, choose a solenoid with a high-temperature resistance rating. In cold environments, ensure that the solenoid can still operate properly without issues like reduced magnetic force.
Humidity and Moisture: In humid or wet environments, a solenoid with waterproof or moisture-resistant properties is required to prevent corrosion and short circuits.
Dust and Chemicals: In dusty or chemically corrosive environments, select a solenoid with appropriate protection, such as a sealed enclosure, to prevent dust or chemicals from entering and affecting its performance.
8.9 Response Time and Precision
Response Time: For applications that require quick action, such as in high-speed machinery or rapid switching systems, choose a solenoid with a short response time. This ensures that the solenoid can activate and deactivate quickly as needed.
Precision: If the solenoid needs to provide precise positioning or force control, look for solenoids with high precision and stability. This is often crucial in applications like robotics and precision manufacturing.
8.10 Reliability and Quality
Brand and Reputation: Choose solenoids from well-known and reputable brands that have a track record of producing high-quality products. This can increase the reliability and lifespan of the solenoid.
Certifications and Standards: Check if the solenoid meets relevant industry standards and certifications, such as UL, CE, etc. This ensures that the solenoid complies with safety and performance requirements.
Part 9 Are there any specific precautions for using frame type solenoids?
When using frame type solenoids, there are several specific precautions to ensure their proper operation and longevity. The details are as follows:
Electrical Connection
Correct Wiring: Ensure that the wiring is connected correctly according to the solenoid's wiring diagram. Reverse connection of positive and negative poles in DC solenoids or incorrect connection of phase lines in AC solenoids can lead to malfunction or even damage to the solenoid.
Secure Connection: The connections should be tight to prevent loose contacts, which can cause arcing, increased resistance, and overheating, affecting the normal operation of the solenoid and potentially posing a safety hazard.
Overvoltage Protection: Do not apply a voltage higher than the rated voltage to the solenoid. Overvoltage can cause excessive current to flow through the coil, overheating the solenoid, reducing its lifespan, and even burning out the coil.
Installation
Proper Installation Location: Select an appropriate installation location that is free from excessive vibration, shock, and strong electromagnetic interference. Excessive vibration and shock can cause the solenoid's components to loosen or become damaged, while strong electromagnetic interference may affect its magnetic field and operation.
Allow Sufficient Space: Leave enough space around the solenoid to ensure good heat dissipation. Blocking the heat dissipation channels can cause the solenoid to overheat and affect its performance and lifespan.
Correct Installation Method: Follow the recommended installation method and torque requirements. Incorrect installation, such as applying excessive force or using the wrong installation tools, may damage the solenoid's casing or internal structure.
Operating Environment
Temperature Range: Operate the solenoid within its specified temperature range. High temperatures can cause the coil's insulation to age prematurely, reduce the magnetic material's performance, and even lead to coil burnout. Low temperatures may cause the solenoid's response time to increase and the magnetic force to decrease.
Humidity and Corrosion: Avoid using the solenoid in humid, corrosive, or dusty environments as much as possible. Humidity can cause moisture to enter the solenoid, leading to short circuits and corrosion. Corrosive gases and liquids can erode the solenoid's metal parts, affecting its performance and lifespan. If it must be used in such an environment, choose a solenoid with appropriate protection levels.
Dust and Foreign Objects: Keep the solenoid clean and free from dust, debris, and other foreign objects. These can enter the solenoid and interfere with the movement of the core, increasing friction and affecting the solenoid's operation.
Maintenance
Regular Inspection: Periodically inspect the solenoid for signs of wear, damage, or loose connections. Check the coil insulation for cracks or discoloration, and inspect the core and casing for signs of deformation or damage.
Cleaning: Regularly clean the solenoid's surface to remove dust and dirt. Use a dry, soft cloth to wipe the surface. If necessary, you can use a mild cleaning agent, but make sure to dry it thoroughly after cleaning to prevent moisture from remaining.
Lubrication: For solenoids with moving parts, apply an appropriate lubricant to the moving parts regularly to reduce friction and wear. However, be careful not to apply too much lubricant to avoid it contaminating the coil or other components.
Operational Parameters
Duty Cycle: Do not exceed the specified duty cycle of the solenoid. Operating the solenoid continuously for too long or with too high a duty cycle can cause it to overheat and reduce its lifespan.
Response Time: Be aware of the solenoid's response time and ensure that it meets the requirements of the application. If the response time is too long or too short, it may affect the normal operation of the entire system.
Part 10 ： Conclusion
Here is a summary of frame type solenoids:
10.1 Structure: The frame type solenoid has a two - piece frame that covers the coil, forming a rectangular shape. This frame structure provides better magnetic field confinement and protection for the solenoid coil.
10.2 Working Principle: It belongs to the category of electromagnets. When an electric current passes through the coil, a magnetic field is generated around the coil. The ferromagnetic plunger is attracted by the magnetic field, causing linear motion, thereby converting electrical energy into mechanical work.
10.3 Performance Characteristics:
Stroke Control: It has a controlled stroke operation, which means it can accurately control the movement distance of the plunger, enabling precise control in applications3.
10.4 Power Compatibility: It can work with both DC and AC power. This versatility allows it to be applied in various electrical systems.
10.5 Compact Design: Some D - frame solenoids have a compact design, which is suitable for applications where space is limited5. For example, in some motorcycle air intake systems, the D - frame solenoid can achieve a long stroke with a small size5.
10.6 High Shock and Vibration Resistance: It can tolerate high - shock and vibration loads, maintaining stable operation in harsh environments. This makes it suitable for use in equipment that may experience vibrations, such as in some industrial machinery5.
10.7 Typical Applications: It is commonly used in ATMs, gaming machines, and gas - and blood - analyzing equipment. In addition, it also has applications in air intake systems, filling, latching, locking, and machine controls.