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Introduction
This article will take an in-depth look at 3-Way solenoid valves.
By reading this article, you will understand more about topics such as:
What are 3-Way Solenoid Valves?
How do 3-Way Solenoid Valves Operate?
Considerations When Choosing 3-Way Solenoid Valves
Parts of a 3-Way Valve
How 3-Way Solenoid Valves Are Manufactured
Types of 3-Way Solenoid Valves
Applications of 3-Way Solenoid Valves
Advantages and Disadvantages of 3-Way Solenoid Valves
And much more...
Chapter 1: What are 3-Way Solenoid Valves and How do They Operate?
A solenoid valve is an electro-mechanical valve for the control of the flow of liquid or gas. There are many solenoid valves, but the two most common are direct-acting (or direct-driven) and pilot-driven (or pilot-controlled). The primary orifice in the valve body is opened and closed by pilot-controlled valves. Pilot-driven valves are the most popular type of solenoid valves. While direct-driven solenoid valves are the only flow path in the valve, they directly open or close the primary valve orifice. Direct-driven solenoid valves are utilized in applications or systems that call for modest flow rates or low-pressure differentials across the valve orifice. There are various kinds of solenoid valves. This article focuses on 3-way solenoid valves.
A 3-way solenoid valve is a valve with the body orifice, a cavity, and a stop port as its port connections of directional control as a solenoid valve. The term 3-way (or 3-port) solenoid valve refers to a collection consisting of three ports, making them perfect for switching the direction of flow. 3-way valves have three function versions, including normally- closed, normally-open, and universal, and are utilized for directional control as opposed to 2-way valves, designed for isolation. Until the coil is energized, normally-closed (NC) 3-way valves block the route between the intake and outlet ports. When a valve is defined as normally open (NO), it is open, allowing fluid to pass from the intake to the outlet while blocking the exhaust port when the coil is de-energized. Since universal valves can accept flow in any direction, they can be piped as either NC or NO and utilized for choosing or diverting flow purposes.
The 3-way solenoid valve has two orifices, the stop orifice and the body orifice, which is always open. This design enables two flow pathways. First, the plunger is raised or lowered when the valve is activated. By raising the plunger, the stop orifice is sealed off, and the body orifice is opened, allowing flow through the valve's body. When the plunger is depressed, the body orifice is sealed off, the stop orifice is opened, and the flow is directed through that port.
How do 3-Way Solenoid Valves Operate?
Gas or liquid flow in a pipe can be closed, opened, dosed, distributed, or mixed using 3-way solenoid valves. A solenoid valve's circuit function communicates the precise purpose of the device. These solenoid valves use different operating principles most suited for an application. All solenoid valves, however, operate according to the same fundamental principle. A 3-way solenoid valve is operated electrically. The valve has a solenoid, an electric coil with a rotating ferromagnetic core (plunger) in the middle. The plunger seals off a tiny opening when it is resting. The coil produces a magnetic flux when an electric current flows through it.
The orifice is opened when the magnetic field propels the plunger. This is the essential concept underlying the opening and closing of solenoid valves. A solenoid and a valve body are the two primary parts of a solenoid valve. An iron core known as the plunger is encircled by an electromagnetically-inductive coil in the center of a solenoid. The coil is surrounded by housing, often composed of iron or steel, which concentrates the magnetic field produced by the coil.
A 3-way solenoid valve might be normally-open (NO) or normally-closed (NC) when at rest. A normally closed valve is closed, and a normally open valve is open in the de-energized state. The coil is made up of many turns of tightly-wound copper wire. An electrical current passes through this wire, producing a strong magnetic field or flux. When an electrical current is passed through the coil's windings, a small spring fastened to one end of the plunger is overcome by the magnetic flux produced inside the coil's body, which attracts the plunger. A solenoid works by converting electrical energy into mechanical force. If the valve is ordinarily closed, lifting the plunger causes the seal to activate, opening the orifice and allowing media to pass through the valve. If the valve is ordinarily open, the plunger descends, causing the seal to shut the orifice and halt media flow. The shading ring (or shading coil) stops the AC (alternating current) coils from vibrating and buzzing. A shading coil or shading ring is the face of the magnet assembly or the armature of an alternating current solenoid that has a few turns of an electrical conductor, often copper or aluminum. The shading coil's main functions are to provide a sizable phase-shifted magnetic field, prevent mechanical damage to the magnet and power contacts, and avoid undesired noise.
Considerations When Choosing 3-Way Solenoid Valves
Type of Medium
Different materials are used to create solenoid valves. It may be made of bronze, aluminum, steel, or plastic. These materials' varying chemical characteristics will affect how well they can withstand corrosion. Therefore, the medium compatibility of the materials is crucial when choosing a solenoid valve. From there, one can choose the valve housing's material based on the media's chemical makeup and temperature.
Plastic has a reputation for withstanding many media. However, if the medium is excessively hot, it performs poorly. Metal solenoid valves are preferable for hot fluids. The valve must be made of materials compatible with the fluid's acidic or alkaline components. If fluids intended for human consumption are the sort of media to be regulated, stainless steel valves are the most suggested option.
Working Principle
There are various varieties of three-way solenoid valves with various operating principles. There are three solenoid valves: direct, semi-direct, and indirect or pilot acting. One must ascertain whether a direct, indirect, or semi-direct operated solenoid valve is required for an application. Direct-controlled valves work well when simply opening and shutting off are required, together with minimal closing force. The largest flow lines and situations requiring extremely strong closing forces are best suited for a pilot solenoid valve. A typically open solenoid valve is appropriate if the valve is intended to be open most of the time.
Voltage
Different voltages of solenoid coils are available for both direct current (DC) and alternating current (AC). The 3-way solenoid valve type that is chosen depends on safety concerns and the power required. When compared to AC valves, lower DC voltage valves are safer. They are, however, less potent. Uncomplicated 12V solenoid valves would be adequate unless heavy valve closing forces are required.
Type of Environment
Depending on its application, a solenoid valve may be exposed to either a harsh or a gentle environment. For instance, agricultural applications will likely expose an irrigation three-way solenoid valve to harsh external elements that necessitates it be constructed of climate-resistant materials.In settings where external elements aren’t as much of a factor, meanwhile, one could choose a sprinkler solenoid valve made of strong and long-lasting material, like metal. Moreover, an explosion-proof valve is required for explosive environments, whereas a dust-proof valve is needed for dusty surroundings.
Response Time
A valve's response time is the amount of time required to go from the open to the closed position or vice versa. Response times differ among solenoid valves. The reaction time is influenced by the valve's design, the coil's characteristics, air pressure, and the medium's viscosity. DC valves respond a little more slowly than AC valves do. In general, direct-working valves operate more quickly than indirect ones. Due to the potential water hammer issue (where a pressure surge is created in a piping system when a fluid is forced to instantly stop flowing or change flow directions), fast response valves are not recommended in particular applications. Pressure waves may be created by a solenoid valve operating too quickly, endangering the system and its pipes.
Pressure Range
A 3-way solenoid valve selection depends on the system's operating pressure. The valve may burst or sustain damage if the specified maximum pressure is exceeded, which could result in unsafe circumstances. Therefore, the valve must be strong enough to withstand the highest pressure necessary for the application. In addition, various fluids have different pressure values. This makes it crucial to consider the system pressure and the kind of medium when selecting the appropriate valve pressure values.
Temperature Range
One must verify that the valve materials can withstand an application's required minimum and maximum temperatures. Valve capacity must also consider temperature because it impacts the fluid's viscosity and flows. It is not advised to go above the indicated temperature limits. If a fluid’s temperature is too high, one can burn the valve's coil.
IP Rating (Ingress Protection)
The IP rating or code of a solenoid valve stands for “Ingress Protection,” and refers to the amount of protection provided by a material against dangerous parts and the ingress of water, dust, and body parts. It is an accepted global standard and typically has two digits. The first digit represents the level of defense against object entrance and access to potentially dangerous components. The second digit represents the level of moisture protection.
Valve Size and Threading
Threading facilitates installation and firmly fastens the valve to the line. One should be careful in choosing both the appropriate threading and valve size for the system. The valve size needs to be compatible with the system's flow capacity. The valve size must not only meet normal flow requirements, it should be higher for emergency situations. A capacity that is too great, however, would be useless and wasteful.
Stroke
Stroke refers to the length of time it takes a plunger to stop moving. The solenoid's initial force is typically a function of the stroke, i.e., the longer the stroke, the lesser the force. Therefore, it is necessary to understand the force vs. stroke connection before using any solenoid.
Seal Material
Ethylene propylene diene monomer rubber, nitrile butadiene rubber, and fluoroelastomer are the three seal, or diaphragm materials that one can use depending on the chemical characteristics and temperature of the media. However, seals can hinder the flow of media and can be dangerous, especially if the media is intended for consumption.
Operating Time
The type of valve chosen can either be normally open or normally closed, depending on the working period. A typically-closed valve is preferred (and vice versa) when the valve's opening or shutting time is shorter (or longer).
Chapter Two: Parts of a 3-Way Solenoid Valve and How They Are Manufactured
Parts of a 3-Way Solenoid Valve
Body
The solenoid assembly is attached to this section of the valve. The circuit carrying the fluid to be controlled is connected to the valve body. The body also has three ports that connect to the solenoid valve. The valve body transports the circuit's media, and it should be able to do so without harm. Because of this, producers typically employ the best and highest-grade material to create this component.
Coil Windings
The solenoid valve coil consists of a wire that has been coiled around a magnetic core. The coil is the solenoid valve actuator assembly. It causes the movement that shifts a disc or seal, stopping the media from flowing through the 3-way solenoid valve. Various parameters, including the size of the solenoid valve coil, influence the solenoid valve's strength and closing power.
Plunger
A plunger is the component of a three-way solenoid valve that moves to close or open the valve. It is often formed of ferromagnetic material and is cylindrical. The plunger goes upward or downward when the solenoid coil energizes and generates a magnetic field. The movement of the plunger controls the media in the valve, depending on the desired action and the valve's operating mechanism. For example, the plunger could permit the fluid to pass, obstruct it, or control how much is allowed to flow. A seal that shuts the opening is housed in the plunger. The seal may be made of metal or rubber. The most prevalent seals are rubber ones.
Inlet Port or Cavity Port
As the name suggests, the media enters a solenoid valve through its inlet port. It is the opening through which fluid enters the valve before coming into contact with the valve seal or disc, which closes or opens the valve. Depending on the desired function, a 3-way solenoid valve may have one or more inlet ports.
Outlet Port or Body Orifice Port
This port gives the controlled fluid a way out. This area of the valve receives the media that the valve has partially or completely let through. Similar to the input port, a 3-way solenoid valve may have one or more outlet apertures, depending on how it functions.
Stop Port
Sometimes the third port of a three-way solenoid valve is referred to as the stop port because of its functionality. It is the port that regulates the flow of the gas or liquid. In addition, it might be connected to the external environment as a safety valve for cases when pressure increases, for example, a boiler.
Solenoid Coil
The solenoid coil is used as a switch for 3-way solenoid valves. This coil acts like a magnet and the solenoid’s body is drawn to it when current flow is wanted.
Solenoid Spring
The solenoid spring supplies the necessary tension to hold the plunger in position. The plunger may remain stuck up or down the sleeve; it slides in after the coil's current stops flowing due to residual magnetism. This spring prevents the current from flowing by drawing the plunger back to its initial position. Furthermore, the solenoid spring stops the plunger from descending the tube owing to gravity.
Lead Wires
An electric actuator is used to operate a solenoid valve. That implies that wires for carrying current will be present. These are the lead wires, the external connectors that link to the power supply on one end, and the electrical circuitry of the valve on the other. Current is forced to flow through these lead wires and into the solenoid valve when plunger action is required.
Orifice
The orifice is the gap between the input and output ports. This solenoid valve component, controlled by the plunger, limits the flow of media into and out of the valve. Depending on the necessary activity or operating principle used, one or more orifices will be present on a three-way solenoid valve.
Sealing Disc or Gasket
The sealing disc, or gasket, is the element that closes the valve. It should therefore be made of a high-quality material that can withstand corrosion. Additionally, it must be kept clean to prevent the valve from partially closing.
Diaphragm
The diaphragm, used in pilot-operated solenoid valves, uses pressure differences to close the main orifice. The diaphragm, a moving component, must be kept clean for the valve to function properly.
Armature Tube
The armature tube is the hollow part that serves as the plunger’s guide. Any flaws in the tube could result in the plunger jamming because of the limited clearances. Additionally, dirt can impede the plunger's motion, resulting in heat and damage to the valve.
How 3-Way Solenoid Valves are Manufactured
The material chosen for the valve body should be fluid-compatible. The bodies of solenoid valves are mostly made of stainless steel, aluminum, brass, plastic, and brass. Additionally, the seals must work with fluid. The core, plug nut, shade ring, springs, and other components are also exposed to fluids, requiring them to be fluid-compatible to facilitate simpler sealing. The core tube must be non-magnetic to allow the solenoid's field to pass through it and the plug nut. Iron has high magnetic characteristics and is often used for the core and plug nut, but it is more prone to corrosion. Because stainless steel is both magnetic and non-magnetic, it is frequently used.
The manufacture of 3-way solenoid valves involves a complex process. Each major component is made individually. Often, there is a checklist entailing the names of spare parts and materials for each. Discussed below is the common method of how 3-way solenoid valves are manufactured.
Forged Method
In essence, 3-way solenoid valves allow design engineers to switch (divert) between two purposes or to merely dump flow where it is not required, greatly expanding the range of tasks that fixed displacement pumps are capable of. Electronics, manual methods, solenoid coils, and hydraulic oil can all be used for actuators. Some complicated systems even incorporate two or more actuation techniques to maximize performance.
Cutting the materials into the required sizes comes next, after the material has been chosen. The next step is partially heating each component to a specific temperature to forge it. Trimming comes next. Here, extra material or the burr is taken out. After that, the body is flashed to shape it into the proper valve shape. The valve is then smoothed and cleaned by sandblasting. The specifications or requirements of the customer determine sand size
After the sandblasting process, the valves are sorted to get rid of the bad ones. Again, based on the design and the customer's needs, machining is used to improve the sizes and shapes of the threads and holes. Finally, certain acids may be used to treat the surface of the valve.
Assembly
It is crucial to adhere to the correct valve assembly techniques during the manufacturing process. In the assembly step, workers connect each valve component to another. The assembly of a 3-way solenoid valve is frequently carried out by hand. First, the industrial valve's main parts should be cleaned and put together individually. Then, after production is complete, the individual must put the components together to form a full valve. In most cases, the valve body is used as a reference part during the valve assembly process.
Pressure and Leak Tests
3-way solenoid valves are tested for leaking under pressure during the pressure test phase. The tests should be able to tell if the valve is fit for work. In some instances, air, with a pressure of 6 to 8 bars (87 to 116 psi) enters the closed valve for a predetermined period. Depending on the size of the valve, it could last anywhere from two hours to a day. The applied pressure cannot fall below the valve's rated working pressure, and the sealing surface must remain leak-free during this time. The 3-way solenoid valve is repaired if a leak develops during this period. If not, the valve will go to the following stage.
Inspection and Quality Control
Quality control and inspection are the final steps in producing industrial valves. Here, engineers examine each valve to ensure no leaks or errors are present.
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Chapter Three: Types of 3-Way Solenoid Valves
3-Way Direct-Acting Solenoid Valves
Direct-acting solenoid valves use the armature movement to directly perform the solenoid valve's Open/Closed function. A direct-acting solenoid valve has an attached seal disc and a solenoid plunger that immediately opens or closes the orifice.
These 3-way direct-acting solenoid valves are often inexpensive, have a small coil that offers decreased power consumption and reduced heat, and are perfectly suited for actuator and cylinder control applications. In addition, they work without the need for any pressure differential. These 3-way direct-acting solenoid valves come with a brass, plastic, or stainless steel body and are appropriate for most general-purpose media applications. Direct-acting solenoids operate according to straightforward principles. They don't utilize a diaphragm since the moving core provides their seal, and they stay closed even when no pressure is applied. In contrast, a pilot-operated valve needs to be under pressure in order to remain closed.
3-Way Semi-Direct-Acting Solenoid Valves
3-way semi-direct-acting solenoid valves combine the characteristics of direct-acting and indirect-acting solenoid valves. They can manage a relatively high flow rate while operating at zero bars (0 psi). Except for the plunger being directly attached to a movable membrane or diaphragm with a small aperture or hole and pressure chambers on either side, these 3-way solenoid valves resemble indirect valves. The very potent coils in 3-way semi-direct-acting solenoid valves require a minor increase in energy consumption.
3-Way Indirect/Pilot-Acting Solenoid Valves
Three-way pilot-acting solenoid valves are opened and closed according to the differential pressure of the fluid over the valve ports. These valves, also known as servo-assisted solenoids, feature low power requirements, large operating pressure ranges, and high flow rates. A servo-assisted solenoid valve with pilot control uses a small chamber directly above the diaphragm to help the valve work. Process fluid can enter the chamber through a tiny opening in the entrance port. A usually- closed valve maintains the closing seal by compressing the diaphragm and pushing it up against the seat.
The pilot fluid in the chamber is driven back through the aperture at the inlet port and rejoins the main flow through the valve body once current is given to the pilot solenoid. This current pulls the diaphragm higher against the spring pressure.
3-Way Normally-Open Solenoid Valves
The stop port, body cavity port, and body orifice port are the three pipe connections on a three-way normally-open solenoid valve. The body orifice and the stop orifice, which are always open, are its two orifices. This enables two flow pathways. The plunger is raised when the power is turned off, sealing the stop orifice and permitting flow through the valve from the body orifice port and out the cavity port. The plunger descends and closes the body orifice while opening the stop orifice if there is power. This descent creates a path for media to flow from the cavity port to the stop port.
3-Way Normally-Closed Solenoid Valves
The cavity port, body orifice port, and stop port are the three pipe connections on a three-way, normally-closed solenoid valve. The body orifice and the stop orifice, which are always open, are its two orifices. This enables two flow pathways. In contrast to the normally-closed one, the 3-way normally closed solenoid valve shuts off the body opening when the power is turned off while opening the stop opening. As a result, the body orifice and stop orifice are both opened, allowing flow from the cavity port through the valve and out the stop port. As soon as the coil is turned on, the plunger is raised, blocking the stop orifice and opening the body orifice, allowing flow from the body orifice port out the stop port and through the valve body.
3-Way Directional-Control Solenoid Valves
The cavity port, the body orifice port, and the stop port are the three pipe connections on a 3-way directional control solenoid valve. The body orifice and the stop orifice are its two orifices. Since one of the orifices is constantly open, two separate flow paths are possible. When the power is turned on, the plunger rises or falls; rising causes the body orifice to open, sealing off the stop orifice and allowing flow through the valve's body. When the plunger is depressed, the body orifice is sealed off, the stop orifice is opened, and the flow is directed through that port.
3-Way, 2-Position Solenoid Valves
Three port designs are commonly seen in 3-way, 2-position solenoid valves, providing flow routes in various configurations despite only joining two ports in any given position. This valve comprises several tapered cylinders with decreasing cylinder sizes from top to bottom. The 3-way, 2-position solenoid valve fits perfectly into a port with a machined cavity. The two potential pathways—a supply port, where pressure only exists when the valve is opened, and a tank port, which serves as the hydraulic fluid reservoir—are divided by a seal. The cylinder inside the design of this spool-type valve swings back and forth while work is done, allowing pressured hydraulic fluid to flow to either one of the ports, depending on the function needed. In essence, these valves allow design engineers to switch (divert) between two purposes or to merely dump flow where it is not required, greatly expanding the range of tasks that fixed displacement pumps are capable of. Electronics, manual methods, solenoid coils, and hydraulic oil can all be used for actuators. Some complicated systems even incorporate two or more actuation techniques to maximize performance.
Internally Piloted 3-Way Solenoid Valves
A 3-way piloted solenoid valve has a piston that seals the main valve seat. When the valve is closed, pressure builds up on the sides of the piston from a bleed orifice. When there is a pressure differential between the inlet and outlet ports, the valve is shut off. As the pilot valve opens, pressure is relieved from the piston, and the valve opens. Internal piloted 3-way solenoid valves require little pressure differential for opening and closing.
Externally Piloted 3-Way Solenoid Valves
When an externally piloted 3-way solenoid valve is unpressurized, the valve seat is closed. As the valve is energised, the piston raises, and the valve opens. The actuation of an externally piloted 3-way solenoid valve requires the use of an independent pilot medium, which is connected to the top of the actuator.
Chapter Four: Applications, Advantages, and Disadvantages of 3-Way Solenoid Valves
Applications of 3-Way Solenoid Valves
A solenoid-controlled vent valve is typically employed for directing the exhaust of steam from the chamber into a condensing coil situated within a water reservoir.
When combined with 3-way solenoid valves, smaller construction equipment with fixed displacement pumps can perform multi-directional functionality. These valves get over the inherent drawbacks of constant flow by altering the flow channel as needed by a particular application, such as from up and down movement to lateral or tilt movement. As opposed to the conventional solution of increasing the size of the valve and pump to produce increased flow, 3-way solenoid valves provide a more affordable and more compact solution.
A solenoid valve de-energizes and releases any air in the circuit of a compressor.
Several 3-way solenoid valves can be a cost-effective solution for cases where the circuit designer needs to switch the flow from one leg of a circuit to another by simulating a conventional directional spool valve in a customized manifold layout. These valves can also be combined to suit particular functional and space requirements if dumping is necessary and the system requires more than one additional function.
Three-way solenoid valves can also benefit applications where flow is not constantly required. For example, in contrast to variable flow pumps, fixed displacement pumps can only halt the flow by turning the engine off, which also stops all equipment operation. In contrast, 3-way solenoid valves allow for equipment to operate while fluid flow is stopped.
3-way solenoid valves perform well in applications where the fluid is put into and taken out of a holding pattern when functions stop and then start. However, poppet-style solenoid valves (which feature a stemmed tip or ball to shut off a passageway through a combination of fluid pressure and spring force) are advised for applications like bucket lifts, where a valve must maintain loads for a longer period.
3-way solenoid valves are also utilized in energy and medical facilities. These valves can be connected to electrical devices, pressure gauges, and controllers.
Advantages of 3-Way Solenoid Valves
The solenoid-pilot design has the benefits of high flow capacity, dependability, and low power consumption. A direct-acting solenoid has the benefit of not requiring a minimum pressure.
3-way valves are more cost-effective for mixing and diverting applications than numerous two-way valves. Three-way valves are the best choice for heating and cooling a variety of media, including water, oils, and chemicals, because they may mix fluids from multiple inlets.
3-way solenoid valves provide a less expensive option over utilizing many 2-way valves to divert and mix fluids.
Fluids can be mixed or diverted to achieve two different goals using a 3-way solenoid valve.
Varieties of 3-way solenoid valves are available for both high- and low-temperature use.
3-way solenoid valves can be remotely operated.
3-way solenoid valves are compatible with AC and DC voltage.
These valves can be installed either horizontally or vertically.
Disadvantages of 3-Way Solenoid Valves
Their electromagnetic field is either weakened or strengthened when the voltage deviates from the optimum value, causing issues for the valve.
The valve plunger requires a minimum pilot pressure to be shifted.
When mixing, a 3-way valve can only be employed at low differential pressures.
A 3-way solenoid valve is sensitive to voltage.
A control system must remain on while a 3-way solenoid valve is in use.
The solenoid valve may still only partially close if the magnetic field is properly aligned.
A 3-way solenoid valve's coil has to be replaced at some point during its lifespan.
a 3-way solenoid valve can be damaged if the material of its construction is not compatible with the fluid passing through it.
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