REPARING INDUSTRIAL WOUND SOLENOID COIL TO RESTORE PRODUCTIVITY
REPARING INDUSTRIAL WOUND SOLENOID COIL TO RESTORE PRODUCTIVITY
Case Study
Type
Customer
Challenge
Keeping Critical Manufacturing Equipment Operational
The manufacturing industry involves large-scale production in factories that use highly specialized equipment. Though the scale of operations is industrial, the little details are still critical. The factory floor is an interconnected network of machines, and if even one of them goes down for any reason, production grinds to a halt. This is why it’s critical to ensure that all the components of every machine on the factory floor are in good working condition.
Solenoid coil, or electrical devices that trigger the movement of an armature, are frequently a cause for concern. They undergo constant stress when machines are in use.
Velatron Technologies: The Solenoid Coil Specialists
Solenoids are widely used in an array of machines. They are simple devices, consisting of three main parts:
Generates the magnetic field when electrical current flows through the winding.
A movable plunger that responds to the magnetic field and creates the required mechanical movement.
Supports and protects both the winding and the armature while maintaining proper alignment during operation.
When electricity travels along the coiled wire, it creates a magnetic field that moves the armature. Once the current stops, the armature snaps back into place. In the simplest linear solenoids, this creates a back-and-forth motion.
Velatron Technologies has been making custom electromagnetic components since 1945 and has designed and produced custom solenoids for a wide variety of projects. Its experience has put it in good standing after completing a recent project, which required the creation of a custom solenoid coil.
A Solenoid-Related Stoppage
Solenoid Solutions from Velatron Technologies
Since there was no information about the older solenoid readily available, the solution had to be engineered from scratch. The first step was taking apart the calendering machine’s contactor and removing the defective solenoid winding.
Finding the right solution took place over three stages:
- Information Gathering
- Consulting with client’s technicians to gather electrical data
- Studying the performance of similar solenoids
- Analyzing the earlier defective solenoid to identify design flaws and potential improvements
- Modeling and Testing
- Creating a new coliform wound component model using software
- Building a prototype based on the model
- Measuring prototype performance against modeled performance
- Installation
- Adjusting the coil’s design to achieve the client’s desired results
- Replacing the solenoid coil with the new design which was completed and validated in under a week after initial contact with the customer
Damaged Coil
Rewound and Assembled in its housing
Results of Using a Custom Solenoid Coil
The effectiveness of a custom solution, especially when it comes to electromagnetic components, should never be underestimated.
“[Velatron Technologies] team leapt into action, reverse engineering the coil, procuring the unique components and material needed to build a custom part for our application, and building it in record time. They provided a reliable solution in a fraction of the time it took us to track down a spare. They went on to provide a second, brand new coil as a spare for the remaining contactors. Thanks to their team, we will not have to resort to used parts in the event of a future failure.”
Project Insights
There were many lessons to be learned throughout this urgent, time-bound project. Some of the most important insights include the following:
We are one of the few manufacturers in North America that have the capability to universal wind and have done millions of units since our inception. If you are looking for help in magnetics including custom transformers, inductors, coils and windings; contact us below.