CHAPTER-I

Introduction

Actuators is defined as energy converter which convert

one form of energy (electrical) into mechanical energy in a
controlled form. Electromagnetic actuator which converts
electrical to magnetic field is called Solenoid. A Linear Solenoid
is an electromagnetic device that converts electrical energy into a
mechanical energy pushing or pulling force or motion. When
electrical current applied to a conductor in generates magnetic
field. The pole is determined by the direction of current flow
within the conductor (wire). This wire coil becomes an
Electromagnet with its own north and south poles just like the
same as that for a permanent magnet.

One of the reasons for using magnetic fields instead of

electric fields is the higher energy density in magnetic fields. The
air gap between stationary member (stator) and a moving member
of an electromechanical actuator is where the electromechanical
energy conversion takes place. The amount of energy per unit
volume of air gap for magnetic fields can be five times the
magnitude higher than that of electric fields. Lorentzs law of
electromagnetic forces and Faradays law of electromagnetic
induction are the two fundamental principles that govern
electromagnetic actuators. From the armature design point of
view, linear solenoids are divided into four families of solenoid
actuator geometries solenoids with disk, plunger, conical, and
ball armatures .The variables of the optimization study are the
solenoid geometry, magnetic material properties, and
electromagnetic circuit including coil parameters.

Utilized mathematical models would couple the

electrical, mechanical, hydraulic, and from the armature design
point of view, linear solenoids are such as ANSYS are available.
Operating principle in [8] of Linear and Rotary Solenoid actuator.

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Design, finite element analysis and duty cycle [9] of all types of
solenoid actuator. Divided into four families of solenoid actuator
geometries solenoids with disk, plunger, conical, and ball
armatures .The variables of the optimization study are the
solenoid geometry, magnetic material properties, and
electromagnetic circuit including coil parameters. Utilized
mathematical models would couple the electrical, mechanical,
hydraulic, and Magnetic systems of these devices by taking into
account the nonlinearity of the magnetic materials, eddy
currents, and motion.

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 CHAPTER 2

1 Magnetomotive Force and Magnetic Field Strength

When a length of conductor is wound to form multiple

current-carrying loops side-by-side, the magnetic fields
associated with the individual loops combine to create a magnetic
field acting lengthways through the coil as shown in Fig. This
magnetic field is present while current flows through the
conductor but collapses when the current ceases to flow if the
source of electricity is removed.

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 If a piece a magnetisable material is placed within
this field, it will experience a force referred to as a Magnetomotive
Force. The force experienced will of course depend on the
intensity or strength of the magnetic field. The magnetomotive
force should not be thought of as a physical Newtonian force,
(though it often results in this), but rather as analogous to the
electromotive force of a battery or electrical supply. In this case,
the magnetic flux is thought of as analogous to the current
flowing in the loop of in an electric circuit. Magnetomotive Force is
formally defined as the force tending to induce alignment of the
magnetic domains within a material to form lines of flux under
the influence of a magnetic field.

The coil shown in Fig consists of N closely wound turns with

the conductor fed with a current I, so that the magnetic field
created within the coil is uniform and continuous. A piece of
magnetisable, or previously magnetised, material is placed inside
the region within the coil. The magnetomotive force experienced
by the material is directly proportional to the current, I,
generating it and the number of turns, N, of the coil.

Magnetomotive Force is given the symbol MMF and has SI Units

of Amps (A)

Magnetomotive Force MMF Current x No.

TurnsN I (A)

Strictly, the units are those of current, i.e. Amperes, in the

SI system. This, however, tends to hide the fact that the force
depends on the number of turns of the coil and consequently the
units are often stated as Ampere-turns (At), where the number of
turns is in effect dimensionless.

Magnetic Field Strength is defined as the magnetomotive force

experienced per unit length in a uniform magnetic field.

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Magnetic Field Strength has the symbol H and has Units of
Amps/metre (Am-1)

Magnetic Field Strength= Magnetomot ive Force/ Length of

Coiled Path.

H= NI/D

where d is the distance over which the field in the coil is

generated, i.e. the length of the wound coil.

2. Permeability

There is also an intrinsic relationship between Magnetic Field

Strength and Magnetic Flux Density. This is characterised by the
property known as Permeability.

Permeability is defined as the degree of magnetisation which a

material undergoes in response to an applied magnetic field. It is
the ratio of the Magnetic Flux Density to the Magnetic Field
Strength. It is analogous to resistance in an electrical circuit.

Permeability of Free Space: This is defined as the ratio of

the Magnetic Flux Density to Magnetic Field Strength measured
at a distance of 1m from a long straight conductor carrying a
current of 1A as shown in Fig. 3. It is designated as 0 = 4 x
10-7 = 12.57 x 10-7 Hm-1.

The permeability of different materials is usually specified as

relative permeability, r , i.e. relative to free space so that:- 1 r 0
Permeability = Hm

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 From this the Magnetic Flux Density of the field within the
coil can be found as
B= H NI/D

If the wound coil has air as the core then = 0. If, on

the other hand, the core is a magnetic material such as Ferrite,
then the relative permeability of this material must be used.

3 Solenoids:-

The principle of generating a magnetic field within a coil

is exploited in the Solenoid. A solenoid is constructed by winding
a coil on an insulated former. A magnetic/magnetisable shaft is
then inserted into the former so that it is subjected to the
magnetic field which is created when the coil is energised, i.e.
when a current flows through it. Usually, one end of the shaft
protrudes from the former. The magnetised shaft has North and
South poles, which can be aligned in either direction with respect
to the field associated with the coil as shown in Fig.

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 When the coil is energised, the shaft will move under the
influence of the magnetic field in a direction determined by the
rule for poles so that the North pole of the shaft moves towards
the South pole of the field associated with the energised coil.
Alternatively, the South pole of the shaft may be attracted
towards the North pole of the field associated with the coil,
depending on the orientation of both. Fig.

Motion of the Shaft in the Magnetic Field of a Solenoid The

end of the shaft protruding from the former can be connected to
a mechanical actuator, that is, a mechanical mechanism which

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causes some kind of physical action or movement. This will be
forced to move in the same direction as the shaft when the
solenoid is energised. Various mechanical configurations can be
constructed to accomplish a variety of tasks. Often the
solenoid is spring-loaded as shown in Fig.

so that the shaft returns to a neutral position when the coil is

de-energised, i.e. when the solenoid is deactivated. Solenoids
come in a variety of shapes, sizes and power ratings. They are
commonly used in door-lock mechanisms pressure and flow
control valves, pumps and many other industrial applications.

4. DESIGN RULES:-

As previously stated the purpose of this work is to design

rules and models for actuator optimization this section explains
the general procedure introducing all the concepts which are
going to provide such rules. The main steps are: Study of
different plunger type Solenoid actuators.

Design parameters. Study of the geometry and materials of the

actuators.

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 Optimization of Solenoid actuator by placing a non magnetic
spacer, varying the plunger angle, including Bobbin as a
magnetic material and Reducing bobbin thickness.

Analysis and scalability of the actuator.

Comparison of Theoretical, Experimental and ANSYS Results.

The first step introduces the study of linear solenoid

actuators from the armature design point of view they are divided
into four families of solenoid actuator geometries, solenoids with
disk, plunger, conical, and ball armature .Ball-type solenoid
actuators are suitable for fluid control due to their good sealing
capabilities with zero leakage. Ball type armature is not able to
generate force. So it acts like a fluid flow. The disk-type is suitable
for fuel injectors. The disk-type eliminates the armature and the
solenoid acts directly on the flat disk through the core of the
body. Disk solenoid configuration has double the main air gap for
flux to cross. Long stroke (air gap) it generates less force. At the
same time, it has two relatively large surfaces of inner pole and
outer magnetic circuit around a coil where flux is perpendicular
to its surface. This disk and seat design also results in less
deposit build up at the orifice and longer service life. It is not able
to lift the higher weights as plunger and conical plunger.

Plunger solenoid types are the most popular

solenoid configuration with a variety of applications. This is
because the plunger solenoid configuration has a single main air
gap for flux to cross and one parasitic air gap that is usually
perpendicular to the main one. The inner pole surface of the
main air gap carries the flux that is perpendicular to its surface,
especially at the small air gaps where the flux crossing a parasitic
air gap does not contribute to the axial forces Conical solenoid
actuators can be used in long stroke applications, such as in

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automotive door locks, due to their high force over long stroke
capabilities. They can also be applied in situations where the
armature can develop a relatively large force due to a smaller
magnetic air gap than axial stroke.

The conical solenoid configuration has limited applications in

long stroke travel without fast response time. This is because the
conical solenoid configuration has a single main air gap for flux
to cross that is always smaller than mechanical travel distance
and one parasitic air gap that is usually perpendicular to the
direction of motion The Second step introduces a variety of
geometries have mixed configurations taking advantage of
armature geometry features. Each of these basic geometries is
discussed separately because of their different advantages,
helping to serve different purposes.

5 SIMULINK MODELFOR SOLENOID ACTUATOR TO FIND

OUT HYSTERESIS:-

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Hystersis Plot for Solenoid actuator

6 PARAMETERS WHICH THE SOLENOID FORCE :-

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 There are several factors which affect the force developed by
the solenoid. These factors include:

Current applied to the coil

Coil resistance

Ambient (room) temperature

Number of turns on the solenoid coil

Magnetic field density and construction (amount of iron used)

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 CHAPTER 3

1.SUMAARY

In this chapter the following concepts were presented:

The parts of the Electromagnetic Actuator were listed and discussed.

We learned about the two styles of armatures, the pancake and tubular.

The three variations on the tubular shape were presented; flat, conical andproportional.

A discussion on force versus the air gap showed when to use the flat,conical and
proportional shapes.

The various parameters which affect solenoid force were presented along
with what happens when the parameters are varied.

The method to calculate the resistance of a coil when there is a change in temperature was
displayed.

2.CONCLUSIONS

The main objective of the current project is to study the solenoid

actuator for the application of high force generation and to develop a design
methodology for the study of optimization of solenoid actuator. Simulation
model of solenoid has been established. And simulations have been carried
out for time response and Hysteresis. The Electromagnetic analysis has been
established for obtained force and the magnetic force developed by plunger is
correlated with experimental value.

Both analytic and numeric approaches have their advantages. Analytic

models are usually most suitable to show influences of specific parameters
to calculation results. However they can easily become very complicated
even considering quite simple geometries. Therefore it is necessary to

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introduce simplifications wherever possible. Due to simplifications analytic
models often are not that accurate.

3. REFERENCE :-

1. Peter Willard Hammond, Position sensor for mechanically latching

solenoid, US Patent 8319589, Nov 27, 2012

2. Ansys, Low frequency Electromagnetic analysis guide, Ansys Inc,

Release 10.0, (2005).

3. Andrzej, M Pawlak, Sensor and Actuator in Mechatronics Design

and Applications, (2006).

4. Balarama, V.Murty, A New Approach for The Analysis Of Dynamic

Behavior Of Solenoid Actuators With Time Dependent Voltage Input, (1990).

5. Baek-Ju Sung, Eun-Woong Lee and Jae-Gyu Lee, A design method of

solenoid actuator using empirical design coefficients and optimization
technique, pp. 305-34, (2007).

6. Cedrat Technologies, Non linear magnetic actuators, Version 1.1,

(2007).

7. D.Howe, Magnetic actuators, Sensors and Actuators, Vol. 81, pp.268

274, (2000).

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