PNU

Pusan National University MI LAB

Design of Solenoid Actuator for FCV Cylinder Valve using
Electro Magnetic Field Analysis
DongJu Lee, HyoRyeol Lee, JungHwan Ahn, HwaYoung Kim
Introduction
A solenoid actuator is an energy convertor which converts an applied electric signal firstly to electromagnetic energy through a coil subsequently to mechanical kinetic
energy which open a flow channel through the gap formed by a stator and a plunger.
Design of a solenoid actuator requires to determine the maximum attraction force of the solenoid considering the safety factor, to analyze the magnetic flux density,
to decide the solenoid actuator shape, and to calculate the number of windings considering the temperature increase.
In the present study, a solenoid actuator securing operability and structural safety under ultrahigh pressure was designed by combining structural analysis.

Structure & Mechanism

Schematic of solenoid actuator
To open at a rated service pressure of 700bar, a two-step
plunger method was applied to this solenoid actuator.
(a) Initial state (b) Applying an electric current (c) Equilibrium state (d) Flow passage opening
(a) shows the initial state when electric voltage is not applied. In the initial state, the pressure inside the actuator is equal to the pressure
inside the hydrogen container.
(b) shows the state where electric voltage has been applied to magnetize the stator of a magnetic substance and Plunge B is in action.
(c) shows the state where the pressure inside the actuator has been decreased by the discharge of high pressure hydrogen and the pressure
at actuator outlet has been increased to reach pressure equilibrium.
(d) shows a complete opening of the flow channel by the removal of the force applied to plunge A due to the pressure equilibrium.

Design & Analysis

Equations for calculating required solenoid attraction force
This Figure shows the force applied to the plunger in the initial state where electric voltage has not been applied.
Calculated by referring to the EU 406/2010 Annex
: 6.19 N (at the maximum allowable pressure of 875 bar)
: 7.06 N

c : reliability 20 %
15.9 N
Distribution of pressure at initial status

Magnetomotive force equations and analysis of solenoid actuator

Parameters Values
Distance between magnetic poles() 0.9 mm
Magnetic pole area() 45.6 mm22
45.6 mm
Height of coil bobbin() 30.1 mm
Inner diameter of coil bobbin() 30.1
16.7 mm
Outer diameter of coil bobbin() 25.5
16.7 mm
Copper wire diameter()
0.55, 0.5, 0.45, 0.4,
25.5 mm
Voltage()
0.37, 0.35, 0.32, 0.3mm
0.55, 0.5,
120.45,
V 0.4,

Saturation temperature() 0.37, 0.35,
850.32,
0.3mm
Permeability of free space() 12 V

Schematic of coil bobbin Design parameters of solenoid 85actuator

Nd Cd nc mc N I(20) U(20) I(85) U(85)

0.55 0.65 78.15 45 6 270 9.02 2434.59 7.18 1939.29

0.5 0.59 91.43 50 7 350 5.88 2057.80 4.68 1639.16

0.45 0.53 114.2 55 8 440 3.72 1635.10 2.96 1302.45

0.4 0.48 145.3 61 9 549 2.33 1281.12 1.86 1020.48

0.37 0.45 170.6 66 9 594 1.86 1107.64 1.49 882.30

PNU
0.35 0.42 191.2 69 10 690 1.42 977.38 1.13 778.54 Comparison of attraction force with enameled wire diameter at 20 & 85
Pusan National University
0.32 0.39 230 75 11 825 0.98 808.78 0.78 644.24
At 85, the attraction force requirement is satisfied if the enamel coil diameter is equal to or greater than 0.53mm,
0.3 Magnetomotive
0.37 262.9 79 force
11 with
869 enameled
0.82 wire
715.23 diameter
0.66 569.72 because of the decrease of the magnetomotive force due to the increase temperature.

Evaluation of solenoid actuator performance

Attraction force To compare the performance evaluation result with the electromagnetic analysis
Distance between
Maxwell Error rate result, the attraction force generated only by the magnetic force was measured
magnetic poles Experimental
(20) at 20 by removing the spring.
0.1mm 52.77 N 49.83 N 5.57 %
A sufficient time interval was kept between measurements to maintain the coil
0.2mm 46.75 N 44.63 N 4.53 %
temperature at the constant temperature.
0.3mm 41.62 N 38.92 N 6.48 %
0.4mm 37.62 N 34.58 N 8.08 % The measurements were compared with the attraction force obtained by the
0.5mm 34.21 N 31.64 N 7.51 % electromagnetic field analysis, indicating that the error rate was between the
0.6mm 31.16 N 28.52 N 8.47 % minimum of 4.53% and the maximum of 9.05%.
0.7mm 28.5 N 25.92 N 9.05 % The error was caused that 2D analysis was unable to reflect the magnetic flux
0.8mm 26.18 N 23.84 N 8.94 % leakage at the solenoid connector part. In addition, the self-weight of the plunger
0.9mm 24.09 N 22.11 N 8.22 % was not considered in the electormagnetic analysis, while it was reflected in the
1.0mm 22.37 N 20.72 N 7.38 % actual measurements.
Schematic of attraction force test device Attraction force with Distance between magnetic poles

Conclusion
The solenoid actuator design equations were used to calculate the attraction force and magnetomotive force depending on the design conditions and temperature.
The analytical result showed that the enamel wire having a diameter of 0.53mm or greater satisfied the attraction force requirement under saturation temperature condition.
The comparison of the performance test result with the electormagnetic field analysis result showed that the error was within the maximum 10%

Pusan National University / Mechatro-Intelligence Lab.