Why do Solenoid Valves Melt?

Solenoid valves play an important role in construction machinery, but why do they suffer from melting? This question will be explored from three directions: the impact of high frequency operation, the importance of maintenance and servicing, and case studies.

 

Impact of High Frequency Operation

The effect of operating frequency on solenoid valves:

Frequent startup and shutdown of solenoid valves can lead to overheating and melting. High frequency operation leads to rapid changes in the current inside the solenoid coil, which generates additional heat and may also affect the normal operation of other diesel engine parts.

 

Effects of Elevated Temperatures:

As the temperature inside the solenoid valve rises, the resistance of the solenoid coil also increases, which causes the current to rise further. This vicious cycle may lead to thermal damage to the internal components of the solenoid valve.

 

Solution:

To mitigate the effects of high-frequency operation on solenoid valves, consider using solenoid valves with higher ratings, employing soft starters to reduce current inrush, or improving control strategies to reduce start-up frequency.

 

Importance of maintenance and servicing

The need for regular maintenance:

Solenoid valves require regular maintenance, including cleaning, lubrication and inspection. This helps to ensure that the internal components of the solenoid valve work properly, reduces the risk of overheating and melting, and also helps to work with other parts of the unit such as the starter motor and alternator.

 

Importance of cleaning:

Accumulated dust and dirt can clog the passageways of the solenoid valve and reduce the efficiency of heat dissipation. Regular cleaning will keep passages clear and temperatures down.

 

Lubrication and Inspection:

Proper lubrication and regular inspections will ensure that the moving parts of the diesel solenoid valve move freely, reducing wear and tear and lowering internal temperatures.

 

Case Study

Case 1: High-frequency operation triggers melting

At a large construction and engineering company, they use solenoid valves to control a variety of operations in the hydraulic system, including the movement of the arms and buckets of a large excavator. Due to the demands of frequent operation, the solenoid valves were often started up and shut down at a high frequency. This caused the temperature of the solenoid coils inside the solenoid valves to rise, ultimately leading to the melting of several solenoid valves.

 

Solution: The company implemented soft starters to reduce current inrush and replaced the solenoid valves with ones designed to be more resistant to high temperatures. These improvements significantly reduced the problem of melted solenoids and improved equipment reliability.

 

Case 2: Improper Maintenance Leads to Melting

A hydraulic excavator used for civil engineering work was experiencing frequent melting problems with its solenoid valves. Upon inspection, it was found that the machine operator had not been performing regular maintenance. The internal passages were clogged with dirt and deposits, resulting in a severe reduction in the solenoid valve's ability to dissipate heat.

 

Solution: The machine operator took regular cleaning and lubrication measures to ensure that the solenoid valve passages were clear. These maintenance measures helped reduce the risk of overheating of the solenoid valves and extended their service life.

 

Case 3: Design flaws cause melting

A company that manufactures construction machinery found that they were experiencing frequent melting problems with one of their solenoid valve models. After analyzing the problem, it was found that the solenoid valve was designed to dissipate insufficient heat, especially under high-pressure, high-frequency operation.

 

Solution: The company redesigned the solenoid valve with additional heat sinks and a better cooling system to improve its heat dissipation performance. This improvement solved the problem of melting solenoid valves and made them more suitable for high-pressure, high-frequency operation of construction machinery.

 

These case studies highlight the diversity of solenoid valve melting problems and demonstrate ways to address them through improved design, maintenance and operating practices. These lessons learned can be used by other industries and companies to prevent solenoid valve melting problems and improve equipment reliability.