The Journal of Engineering

7th International Symposium on Test Automation and Instrumentation

(ISTAI 2018)

Simulation and optimisation design of the eISSN 2051-3305

Received on 12th October 2018

solenoid valve
Accepted on 9th January 2019
E-First on 12th December 2019
doi: 10.1049/joe.2018.9087
www.ietdl.org

Yunhong Zheng1 , Zongjie Zhou1, Rongsheng Dai1

1Xiamen University of Technology, Xiamen, People's Republic of China
E-mail: zhengyunhong@xmut.edu.cn

Abstract: This study first analyses the problems that the solenoid valve generates during operation. Then the electromagnetic
valve was modelled and ANSYS finite element analysis simulation software was used to simulate the electromagnetic field and
transient magnetic field of the solenoid valve. The magnetic induction intensity distribution diagram and magnetic field
distribution diagram of the electromagnet were obtained. According to the simulation results of the solenoid valve, the magnetic
flux leakage line is blocked after the magnetic isolation cover is added, the magnetic induction strength of the iron core and the
valve head is increased, the leakage magnetic flux is reduced, and the structure is optimised.

1 Introduction 2.1 Basic theory of electromagnetic field

Solenoid valve is a kind of electromagnetic control industrial The differential form of Maxwell's equations is shown in (1)
equipment, which relies on the electromagnetic force generated by
→
the power coil to drive the valve core and open and close the valve. → ∂B
Its main role is to automatically cut off, automatically connect or ∇×E = −
∂t
switch the flow of fluid, which is widely used in industrial control →
systems. Since the solenoid valve is a very important part of the → ∂D
∇ × H = j0 + (1)
automatic transmission shifting circuit, its characteristics will ∂t .
directly affect the characteristics of the entire shifting circuit [1]. →
∇⋅B =0
i. Solenoid valves have some flaws such as large noise, corrosion, →
∇ ⋅ D = ρ0
rust and leakage [2]. Some solenoid valve coils are easily burned
out, and the remanence is too large to be reset in time. This can be
done by limiting the energy, that is, limiting the voltage and current Except for Maxwell's equations, the relationship between field
to ensure normal operation, and the energy generated by quantities E, D, B, H is determined by the characteristics of the
maloperation or failure will not cause an explosion [3]. medium. For linear medium, it satisfies the following three
constitutive relations shown in (2)
ii. Solenoid valves have the disadvantages of low electromagnetic
D = εE
force, low life and slow dynamic response [4]. The main failure
modes of the electromagnets are the lack of suction, that is, the B = μH . (2)
inability to open the valve or the inability to seal, the failure to J = σE
release the armature, close the valve and burn the coil.
In general, solving the electromagnetic field problem requires
To solve the shortcomings of the solenoid valve, based on the simplifying the above equation. For this purpose, vector magnetic
designed method of the solenoid valve, the electromagnetic potentials and scalar potentials are often introduced to separate
numerical simulation, the optimal design of the electromagnetic electric field variables from magnetic field variables. Vector
valve and the dynamic simulation of the electromagnetic valve magnetic potential A is defined as follows in (3)
system can be used to optimise the design of the solenoid valve.
The static and dynamic characteristics of the electromagnetic valve B = ∇ × A. (3)
are simulated and analysed.
There are some studies that show the optimisation of the In general, A is a function of space coordinates and time and
solenoid valve. In [5], the finite element analysis software: Magnet contains three spatial components. In the International System of
was used to optimise the DC electromagnet, and the material of the Units, the unit of A is Wb/m, and the scalar potential is defined in
coil skeleton was determined by using this method, and the air gap (4)
length and the size of the electromagnet top cap were optimised.
So, a reliable and having high, fast response DC solenoid was E = − ∇∅ . (4)
developed. In [6], a generalised gradient method was used to
develop an optimisation algorithm for the design parameters of a By introducing the vector magnetic potential A and the scalar
button electromechanical magnet. The weight was used as the potential, the specific electromagnetic field problem is converted
objective function to optimise the design of the electromagnet. The into the corresponding Poisson equation and Laplace equation, and
literature [7] adopts the sequential quadratic programming method then the differential equations in different fields are numerically
to carry out volume optimisation design of intrinsically safe solved.
electromagnets.

2 Methodology

J. Eng., 2019, Vol. 2019 Iss. 23, pp. 8701-8705 8701

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Fig. 1 Solenoid valve model
Fig. 2 Distribution of magnetic lines distribution
2.2 Boundary conditions in electromagnetic fields
The two media at the interface, the tangential and normal
components of the electromagnetic field must meet certain
requirements, and that is the boundary condition equation. For
example, the magnetic induction intensity distribution of the
energising solenoid satisfies (3), and (5) is Gauss's theorem
∫ ∇ ⋅ B dV = ∮ B ⋅ n dS,
V ∂V
^
where ∂V is the outer surface of the volume V studied and the
conservation law on the boundary surface is applied, which is
given by
n^ ⋅ B2 − B1 = 0,
n is the unit normal vector of the interface from 1 to 2, similarly
^
given by the Poisson equation in (7)
n^ ⋅ D2 − D1 = ρs,
ρs is the charge surface density of the interface, obtained by Stokes'
theorem in (8)
∫ (∇ × E) ⋅ dS = ∮ E ⋅ dl,
S ∂S
∂S is a curve surrounding the surface S, applied to Faraday's law in
(9)
n^ × E2 − E1 = 0.
Similarly, applying Ampere's law in (10)
n^ × H2 − H1 = Js,
Js is the surface current at the interface between the two media.
The electric field strength in the ideal conductor is zero, so the
electric displacement is also zero. When the medium is an ideal
electrical conductor, the boundary conditions are n^ ⋅ D2 = ρs and
n^ × E2 = 0. Under the condition of finite frequency, the magnetic
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Fig. 3 Magnetic induction intensity
induction intensity is zero by Faraday's law, and the corresponding
boundary conditions are n^ ⋅ B2 = 0 and n^ × E2 = Js.
2.3 Energy relationship
In the static magnetic field, the formula for the corresponding
energy density is
ωm = B 2 / 2μ . (11)
In the time-varying electromagnetic field, the energy density is
ω2 = ωm. With this value, the energy conservation equation of the
actual electromagnetic field problem can be established.
2.4 Suction formula
When a current flows through the electromagnetic coil, the coil
generates a magnetic flux. The magnetic flux magnetically attracts
the iron core and the armature so that the armature brings about a
displacement operation to the contact. When the coil is de-
energised, the armature loses electromagnetic attraction and the
return spring pulls it back to its original position, and the contacts
are reset.
There are two forces acting on the armature. One is
(5)
electromagnetic attraction and the other is reaction.
Electromagnetic suction is generated by an electromagnetic
mechanism (core). The reaction force is generated by the return
spring and the contact spring, which is generated by the moving
iron core in the valve head.
Maxwell electromagnetic suction formula is shown in (12)
(6)
1 B2S 107 2
FX = = B S. (12)
2 μ0 8π
Maxwell's software calculated electromagnetic force value as
(7) 22.12 N.
2.5 Solenoid valve model
In the finite element analysis of a static magnetic field and a
transient field, a two-dimensional model of an existing
(8) electromagnetic valve must first be established. Fig. 1 shows a
solenoid valve model.
3 Results
3.1 Simulation model of static magnetic field in initial model
(9)
According to relevant reference materials, the current acting on the
coil of the solenoid valve is determined to be 10,000 A. The mesh
is divided into free meshes. The balloon boundary condition is
used, and the maximum number of converging steps is 10 steps.
(10)
After two-dimensional static analysis of the solenoid valve by
Maxwell software, the magnetic field distribution obtained is
shown in Figs. 2 and 3. Most magnetic fluxes form the main
magnetic circuit through the valve head and the iron core. The
magnetic flux leakage between the iron core, the valve head and
the coil is slightly larger. The closer to the air gap, the more
magnetic flux leakage can be seen, and the valve head and the iron
J. Eng., 2019, Vol. 2019 Iss. 23, pp. 8701-8705
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Fig. 4 Magnetic field strength change on Polyline1 in static magnetic
field: Mag_H
Fig. 5 Magnetic force variation on Polyline1 in static magnetic field:
Mag_B
Fig. 6 Relationship between the size of the exciting current and the
electromagnetic force
Fig. 7 Relationship between displacement and electromagnetic force
core. Diffusion flux occurs between the air gaps. The highest point
of magnetic induction occurs at the yoke close to the valve head.
Draw a line where the magnetic saturation line is most likely to
occur. Name it Polyline1. Observe for saturation.
From Figs. 4 and 5, the maximum value of the magnetic field
strength on the static magnetic field on Polyline1 is 12.8 kA/m, and
the maximum magnetic induction intensity on the Polyline1 is
1.811 T.
Adjust the current parameterisation. Change the current
excitation from 7000 to 13,000 A and increase it by 500 A.
Observe the relationship between the size of the excitation current
and the force (Fig. 6).
As can be seen from the figure, as the current increases, the
excitation also increases. The current excitation changes from 7000
to 13,000 A, and increases by 500 A. The electromagnetic force
also changes from about 13 N to about 34 N.
J. Eng., 2019, Vol. 2019 Iss. 23, pp. 8701-8705
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Fig. 8 Distribution of lines of magnetic force at time point 0.01 s
Fig. 9 Distribution induction of magnetic intensity at time point 0.01 s
Fig. 10 Distribution of lines of magnetic force at time point 0.02 s
Fig. 11 Distribution induction of magnetic intensity at time point 0.02 s
Adjust the displacement, change the displacement from −15 to
15 mm, increment 1 mm, move the valve head along the Z-axis, set
the amount of movement to tt, the unit is mm.
As shown in the displacement curve of Fig. 7, the
electromagnetic force approximates the variation of the quadratic
curve with the size of the working gap. During the upward
movement of the valve head, the electromagnetic force gradually
increases from zero, and the maximum value is about 27 N.
3.2 Analysis of initial model transient field simulation results
3.2.1 Distribution of magnetic lines and magnetic induction at
different time points: After a two-dimensional transient analysis
of the solenoid valve by Maxwell software, the resulting magnetic
field distribution is shown in Figs. 8–13. Most of the magnetic flux
passes through the valve head and the iron core to form the main
magnetic circuit, the magnetic flux inside the coil is less, the
magnetic flux leakage between the iron core and the valve head is
slightly more, the magnetic flux leaks closer to the air gap and the
valve head and the iron diffusion flux occurs at the air gap between
the cores. The highest point of magnetic induction occurs at the
yoke close to the valve head. As the time increases, the valve head
moves upwards, the magnetic induction lines passing through the
valve head increase, and the magnetic induction intensity inside the
valve head gradually increases (Fig. 14).
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Fig. 12 Distribution of lines of magnetic force at time point 0.03 s

Fig. 15 Magnetic intensity diagram at 0.03 s after addition of magnetic

sleeves

Fig. 13 Distribution induction of magnetic intensity at time point 0.03 s

Fig. 16 Graph of speed/force and time

Fig. 14 After adding spacers

3.2.2 Add a magnetic shield to observe changes: After the

magnetic shield was added, the magnetic induction intensity in the
iron core was increased by comparing Fig. 15 with Fig. 13. In
Fig. 15, the strongest point of the magnetic induction intensity is
about 1.210 T. In Fig. 13, the highest point of the magnetic
induction intensity is about 1.215 T. The magnetic separation
magnetic shield blocks the leaked magnetic induction line, so that
the magnetic induction intensity of the iron core becomes high
(Fig. 16).

3.2.3 Other charts: Due to the part of the incentive with

communication, the suction is periodic. When the electromagnetic
force is greater than the load force, the electromagnetic force
continues to increase, and the acceleration also increases.
Therefore, the slope of the speed curve becomes more and more,
and when it reaches 18 ms, it drops to 0 m/s and the valve head
stops moving. The maximum speed during spool movement is 2  valve head and the iron core. The magnetic flux leakage between
m/s.
3.3 Analysis of transient field simulation results by adding
external circuit excitation
The external circuit provides 220 V. The magnetic field strength of
the air gap is changed by the valve head movement to change the
field strength distribution of the entire solenoid valve.
3.3.1 Distribution of magnetic lines and magnetic induction
intensity at time point 0.003 s: Two-dimensional transient
analysis of solenoid valves via Maxwell software: In Fig. 17, when
the time point is 0.003 s, the magnetic induction point is 2.8303 T.
Most magnetic fluxes form the main magnetic circuit through the
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Fig. 17 Distribution of magnetic force lines and distribution of magnetic
induction intensity at time point 0.003 s
the iron core, the valve head and the coil is slightly more. The more
magnetic leakage closer to the air gap, the highest point of
magnetic induction occurs inside the valve head. The core parts:
With the change of time, the magnetic induction of the valve head
is getting higher and higher (Figs. 18 and 19).
3.3.2 Various charts: The speed curve shows that the valve head
starts to generate motion velocity at 0 ms until the 4 ms motion
stops, and the maximum value during valve head movement is
about 1.10 m/s.
As the energisation time of the solenoid valve coil increases, the
maximum value reaches 310 N at 0 ms, the 4 ms motion stops and
J. Eng., 2019, Vol. 2019 Iss. 23, pp. 8701-8705
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Fig. 18 Speed
Fig. 19 Electromagnetic force
the electromagnetic force drops to about 288 N and remains
constant.
3.3.3 Optimisation: A magnetic shield is added to the iron core
and the coil, and the material is copper.
Adding a magnetic shield to observe, comparing Fig. 17 with
Fig. 20, it can be clearly seen that the magnetic induction intensity
in the valve head is increased. In Fig. 17, the strongest point of the
magnetic induction intensity is 2.8303 T, and in Fig. 20, the highest
magnetic induction intensity point is 2.8344 T. The magnetic
separation magnetic shield blocks the leaked magnetic induction
line, so that the magnetic induction intensity of the valve head
becomes high.
The addition of magnetic separators increases the magnetic
induction of the iron core, reduces the magnetic flux leakage and
improves the magnetic strength of the valve head.
4 Conclusion
The static magnetic field simulation mainly analyses the magnetic
field intensity distribution of the electromagnetic field and obtains
J. Eng., 2019, Vol. 2019 Iss. 23, pp. 8701-8705
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Fig. 20 Distribution of magnetic force lines and distribution of magnetic
induction intensity at time point of 0.003 s after magnetic spacers are
added
the point where the field strength is the largest, and it is
parametrically designed to optimise the valve head structure. With
the increase of the excitation current, the force gradually increases;
as the displacement of the valve head increases, the force gradually
increases.
The transient field simulation of compound excitation mainly
analyses the changes of various parameters when the valve head
moves to the iron core. The magnetic shield is added to increase
the magnetic induction strength of the iron core so that the
magnetic flux leakage is reduced.
5 Acknowledgments
The work presented in this paper was funded by the guiding project
of the Fujian Rural Department of Science and Technology
(2019H0039).
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