What Is A Solenoid Coil and How It works ?

Introduction

As a solenoid and solenoid coil manufacturers, we would like to takes an in depth look at solenoid coils application and manufacturing by Dr. Solenoid as below:

Through this cortical,  you will know the topics as below such as:

• What is a solenoid coil and how is work ?
• How solenoid coil is made
• How solenoid coils are application
• What Types of solenoid coils we can offer
• And much more…

No. One ,  What is a Solenoid Coil and how it is work ?

1.1 A solenoid coils are  common electrical components that fixed a copper wire that is tightly wrapped around a core, usually made of carbon metal, to generate an electromagnetic field as a power by application.

How solenoid coil working ?

1.2 When an electrical current is passed through the inside copper coil, the electromagnetic field is created and provides magnet energy for the linear movement motion. By adjusting the small or large current with the machnical device, the solenoid or the solenoid valve is a simplest forms of linear actuation devices for lot of the solenoid and solenoid valve application.

No. Two - How Solenoid Coils are being application?

Our solenoid coils are highly versatile components applied in a lot of devices, from production machinery, smart toys to appliances and various types of automated equipment. Especially, they serve as a switch application on or off. When DC or AC　voltage is passed through the coil, it activates a movable armature, which in turn engages with and activates the connected mechanism.

Solenoid coils feature with diverse applications in industrial procession. They can be crucial in locking mechanisms or play a central role in automated production assembling systems. Usually, a solenoid coil is employed to control hydraulic and pneumatic valves in industrial settings.

How the Solenoid Coils are being application ?

2.1 Smart Locking Mechanisms

A solenoid coil is found as part of an automatic smart locking mechanism, such as smart door locks system for high security areas and restricted access the meeting rooms. When the locking mechanism system is in a locked position, the solenoid coil is power off.  When the power on, the solenoid coil activates and unlocks.

2.2  The Medical Applications

Solenoid coil is a critical components in medical equipment , where precision, accuracy, and reliability are the key requirement. Manufacturers must strictly follow the related standards to minimize the risk of solenoid coil for being failure. For example, in dialysis machines, solenoid coil regulates the blood flow, while dosing machines use them to control medication delivery to patients. Solenoid coil is also employed in various kinds of medical devices, including oxygen delivery machine, diagnostic equipment, patient monitoring equipment, respirators, and gas chromatography systems.

2.3  Automotive

Solenoid coil plays a crucial key in growing automation sys within the automotive industry. They are used for interlocking mechanisms in the gearbox drive selector, which is vital for taking the different drive modes. What is more, solenoid coil is also found in air conditioning controls, entertainment systems, and security applications.

2.4 In Irrigation System

In irrigation industry, solenoid coil controls the water flow by turning the system on and off, opening or stopping the water flow as requirement. Each types of solenoid coils are designed for underground application, featuring a screw for plumbing attachment and wires for electrical activation.

Irrigation solenoid coil is typically connected to an electronic timer that schedules watering at fixing times. However, this kind of the coils can become obstructed by dirt, soil, or other debris, which may cause them to remain open and disrupt their proper function.

2.5 In Aviation

Aircraft feature a strong power distribution bus for the electronic equipment, which is disconnected when the aircraft starter is engaged to avoid voltage spikes. A solenoid coil links the avionics bus, which supplies power to the electronics, with the main power bus. It will activate during engine start-up to temporarily disconnect the avionics bus and prevent potential interference.

2.6 Hydraulic Solenoid

The solenoid coil on a solenoid valve opens, closes, and changes the directional flow of fluid in the system. They are low power switches that open and close solenoid valves that control the main valve in pressure to the connected piston or diaphragm. The choice of hydraulic solenoid valves is affected by its voltage and power consumption.

2.7 Pneumatic Solenoid Valve System

Solenoid coils typically features with either an open or closed position. Solenoid copper Coils in the closed position, it will stop the flow when activated, while the solenoid valve is in the open position allow fluid to flow when activated.

A pneumatic solenoid valve system applies a three way, two position solenoid valve that allows the fluid to be diverted from one channel to another channel and is capable of controlling cylinders bi-directionality. Some pneumatic systems use a five way, three position solenoid valve that has two copper coils inside for controlling purpose.

2.8 Solenoid valve in Pinball Machines

In a pinball machine system, solenoid coil is responsible for propelling the ball when it strikes the bumper, providing a burst of force. The solenoid coil retracts a metal rod to launch the ball and then thrusts it forward. Additionally, solenoid valves power the flippers that push the ball back up to the playing field.

To ensure the machine system operates correctly and to prevent overloading or damaging the solenoid valves, it is powered for only a brief moment.

No. Three - How Solenoid Coils are Made by Dr. Solenoid ?

3.1 Solenoid coils are constructed by winding a wire, especially made of copper or aluminum, around a hollow core. These coils can operate on either direct or alternating currents and are compatible with different DC or AC voltages, including 6, 12, 24, 120, and 220 volts. Low-voltage coils, lower then 24 V, are suitable for smaller applications, whereas higher-voltage coils, above 24 volts, are used in industrial settings and heavy machinery system.

The types of two primary solenoid coil is tape-wrapped and encapsulated. Tape-wrapped coil is used in less demanding environments where exposure to solvents and chemicals is minimal, such as in clocks, timers, pneumatic systems, and electronic circuits.

The related solenoid coils are sealed in protective materials like polyester, rubber, or epoxy. This encapsulation offer the insulation, dielectric strength, and enhanced structural integrity, making these coils suitable for harsh and demanding conditions.

3.2  How Solenoid Coils are being Made by Dr. Solenoid ?

3.2.1 Copper Wire

Copper wire is the most commonly used material for constructing solenoid coils due to its superior specification in conductivity and flexibility. other types of wire may be available, none match the performance of copper. The copper wire classes best suited for solenoid coils are F, H, and N, as they possess the necessary characteristics and properties.

One key factor in applying the copper wire is its diameter. If the wire is too thin, it will increase the coil's resistance, reduce its efficiency, and potentially lead to overheating and burnout. As for us, we always make sure the best performance meet customer specification when applying the solenoid coil in your project.

3.2.2  Class F of Copper coil

The copper wire of class F winding can stand the tolerating temperatures above 155°C and perform effectively in ambient conditions of 20°C, with media temperatures reaching up to 100°C.

3.2.3  Class H of Copper coil

The Copper Coil of Class H winding is capable of withstanding the temperatures over 180°C and function reliably in ambient temperatures of 50°C with media temperatures reaching up to 180°C.

3.3.4  Class N of Copper Coil

Class N of copper coil winding is suitable for hot temperatures exceeding 200°C and can work effectively at ambient temperatures of up to 80°C with media temperatures reaching 200°C.

3.3.5  The Bobbin of Copper Coil

The bobbin of Copper coils serve as the support structure for the copper wire, securing the lead copper wires to prevent strain. Beyond holding the wire, it also locates and guides the movement of the solenoid components and regulates the solenoid's strok. With durability, the bobbin features a low-friction surface and may include connectors, such as DIN connectors, for electrical current supply purpose.

3.3.6  the Winding of Copper Coil

The winding of a solenoid copper coil is determined by factors such as circuit requirements, the inductance value, and the bobbin diameter. The number of winding directly influences the strength of the solenoid's magnetic field, with inductance increasing in proportion to the square of the number of coil turns.

Increasing the number of winding adds more magnetic field power, enhancing the strength of the electromagnetic field. The strength of magnetic filed is affected by the number of copper coils, the type of good or bad copper wire used, and the wire's thickness. As the resistance decreases, more power current will flow through the copper coil, creating in a stronger magnetic field accordingly.

3.3.7 Copper Coil Core

The core of a solenoid coil can be constructed from various magnetic metals, which will enhance the copper coil's magnetic power. When solenoid coils is function without a core, as seen in air-core designs, the metal core material significantly affects the magnetic field strength, with some cores amplifying it by up to 100 times.

Air cores, typically made from glass or plastic, do not increasing the magnetic field strength but upgrading the high efficiency at elevated frequencies, reaching up to one gigahertz (GHz). In contrast, metal cores are limited to frequencies up to 100 megahertz (MHz).

The types of solenoid cores include:

• Alloy Iron
• Electrical Carbon steel
• Ferronickel
• Ferro-Aluminum
• Ferro Cobalt

4.0 Solenoid Coil Protection

There are two primary ways for protecting the copper solenoid wires: wrapping and encapsulating. Wrapped solenoid coils are covered with special paper or tape, when encapsulated coils are sealed within a solid, non-porous material. These methods offer distinct types of protection and durability.

4.1 Wrapped

Wrapped solenoid coil is covered with adhesive tape or paper around the magnetic wires. Most wrapped copper coils are protected by insulated tape to ensure proper insulation and durability while application.

4.2 Encapsulated

Encapsulated solenoid coils are protected by solid materials such as epoxy, rubber, different forms of polyester, and plastic. These types of solenoids are referred to as molded and are capable of withstanding harsh and hazardous conditions.

5.0  DIN Connectors

DIN, for Deutsches Institut für Normung (German Institute for Standardization), establishes standards used in various fields, including electronics. For solenoid coil, DIN connector is used instead of lead wires and feature a male connector that plugs into the another female socket. These connectors provide a more secure connection, facilitating easier coil replacement.

DIN connector is most commonly used with encapsulated solenoid coil, as they can be seamlessly integrated into the bobbin design.

No. 4 - How Solenoid Coil Works?

The key function of a solenoid coil is to convert the electrical energy into the mechanical energy, producing linear motion. The structure consists of a wire wound around a piston made of ferromagnetic material. Unlike a permanent magnet, a solenoid coil can be turned off, making it ideal for using during switches, valves, and automated systems.

Like the comment magnets, a solenoid coil has positive and negative poles that can attract or repel materials sensitive to magnetic forces accordingly. The magnetic field generated by the solenoid causes the core or piston to move forward or backward direction, enabling the activation or deactivation of various applications.

 Two primary elements in a solenoid coil are its magnetic field and electrical input. While a magnet can alter the position or direction of metal objects, it remains continuously magnetized. Solenoid coils, however, can control their magnetic fields through electrical activation, allowing for precise control.

All copper wires generate a weak magnetic field when electric current flows through the unit. To increasing this effect, copper wires are wound into a coil built in a solenoid. Each loop of copper wire enhances the magnetic field, producing a stronger effect than a single straight copper wire.

Every device needs a electronic circuit between the device and the power source. Switching system provides a reliable on and off  the switching connection. As power demands increasing, the switching size must increase also. Despite this, activating and deactivating the switching requires minimal energy also. Solenoids, therefore, efficiently manage this with minimal energy, such as a 24 V solenoid operating a 240-volt machine.

If a standard switching system were used for large equipment, it would require a very thick wire to handle the necessary power source. Solenoids, however, require less power to operate than the devices they control, allowing for smaller, more cost-effective wiring.

The movement of solenoid coil can activate or deactivate an application. This simple mechanism system enables the control of large equipment with relatively low energy consumption.

Different designs of solenoid coil can achieve different outcomes. A example, in a smart door lock mechanism system, the smart solenoid can stay engaged to keep the door locked. When an electric current is applied, the solenoid’s plunger retracting to unlock the door.

Proportional solenoid coil system converts an electric signal into proportional mechanical force, featuring with adjustments in position and force based on the current. These kind of copper coils are used for regulating flow rates by adjusting the position of a valve’s plunger.

No. Five - What kind of Solenoid Coils we make?

There are large range of solenoid coils designed by us for every customer possible application. These coils are different in design, materials, and intended application. Despite the variety and specific applications, all of our solenoid coil are function based on the same electrical principles.

Solenoid coil is frequently employed as solenoid valve coil for fluid or other liquid control. They is integral to automated machinery and robotic systems. Besides being categorized as wrapped or encapsulated, solenoid coil is further classified by their power source: alternating current (AC) or direct current (DC). The selection between AC and DC depends on the factors related to the specific application of the copper coil.

No. Six  the type of Solenoid Coils

6.1  AC Laminated Solenoid Coil

A AC solenoid is capable of delivering a substantial amount of force on the initial stroke due to the high current input when power on. This characteristic make the coils to produce multiple strokes effectively. AC laminated solenoid coil comes in various configurations and typically produce a buzzing sound. They are well-suited for applications needing rapid response, such as in medical devices, automotive systems, printers, and household appliances.

6.2 Copper Coil for DC C Frame Solenoid

The C frame of a DC solenoid features an open frame design to enable linear motion direction. It represents one of the simplest and most cost-effective solenoid configurations while delivering the high performance.  Both pushing and pulling configurations, it is commonly used in straightforward applications such as circuit breakers, scanners, coin counters, and point-of-sale devices.

6.3 Copper Coil for a Rotary Solenoid

Solenoid coil is typically linear devices that move back and forth. Rotary solenoid coil, however, convert linear motion into a rotary motion by using three ball bearings.

When power on, the plunger of a rotary solenoid is drawn toward the stator and rotates through an arc. These coil generate angular or rotary motion, which can be in a clockwise, counterclockwise, or bidirectional manner.

The movement of a rotary solenoid coil can be set for 25°, 35°, 45°, 60°, or 90°, or it can involve multiple movements at specific angles. This rotary motion can be produced when the coil is energized, de-energized, or when there is a change in the polarity of the electromagnetic field.

6.4 DC - Copper coil for D Frame Solenoid

A DC D frame solenoid is encased in two D-shaped frames on either side. This design provides a slightly higher force output and better resistance to environmental factors. D frame solenoid feature an economical design suitable for high-volume applications and continuous duty, and they are available for both on and off operations.

The different sizes and stroke options of a DC D frame solenoid enable it to deliver reliable performance over several million cycles.

6.5 Copper Coil for Solenoid Valve

The functioin of a solenoid valve is to regulate the flow of fluids in tubes, ducts, and pipes. There are multiple types of solenoid valve with copper coils, each designed to address the specific requirements of different fluid flow applications.

6.5.1 Direct Acting type

Direct acting solenoid valve features a plunger that seals a small orifice without requiring additional force. This type of solenoid operates quickly, can function under pressure, and can be configured as either an open or closed valve coil.

6.5.2 Pilot Operated

The operation of a solenoid valve, also known as an indirect acting solenoid coil, utilizes pressure across the valve port to control the valve's opening or closing. When power on, the copper coil opens the valve, while the system's pressure maintains the valve in a closed position.

6.5.3 Two Way

The two-way solenoid valve features two ports that can open or close to regulate fluid flow. These solenoid valves are applied where controlling the release or restriction of fluids is necessary, such as in air compressors.

6.5.4 Copper Coil For Three Way of Solenoid Valve

The three-way solenoid includes three ports and two openings that alternate based on the coil's option. Two of the ports work as inlets, while the third port act as an outlet. This configuration allows for the control of two different fluids.

6.5.5 Copper Coil For Four Way of Solenoid Valv

The four-way solenoid valve features an additional port, with two ports working as inlets and the other two as outlets. This design is used to operate double-acting solenoid valve actuators.

Summery

The solenoid coil is a common electrical component that apply a wire that is tightly wrapped around a core, usually made of metal or plastic inside, to generate the electromagnetic field when the power current getting through.

• The electromagnetic field in the core of a solenoid coil pulls the plunger against the spring tension of the core; this linear motion to activate a switch, ring a doorbell, or turn on a paintball gun.
• Solenoid coil is a very versatile tool that can be found in production machines, toys, appliances, and various forms of automated equipment.
• The construction of solenoid coils involve a wire, copper or aluminum, that is wound around a bobbin inside.
• The purpose of a solenoid coil is to convert the electrical energy into mechanical energy to supply linear motion.