Linear solenoids Manufacturers online

Linear solenoids are electromagnetic actuators that generate a magnetic force when a coil is energized, which attracts or repels a movable armature.

They convert electrical energy into a linear mechanical movement. Linear solenoids are used wherever fast, simple and reliable linear movements are required without resorting to complex mechanical drives.

Below you will find the functionality and types of linear solenoids, their use as well as their advantages, challenges and limitations:

How linear solenoids work:

The way a linear solenoid works is based on the electromagnetic principle. When current is passed through a coil, a magnetic field is created. This magnetic field pulls a ferromagnetic armature in the direction of the magnetic circuit.

Typical process:

1. Current flows through the coil and generates a magnetic field.
2. The magnetic flux closes over the yoke and armature.
3. The armature is pulled in the direction of the coil with a force.
4. After the current is switched off, the armature moves back, usually due to a spring or gravity.

The force generated depends on several factors, including the current strength, the number of turns of the coil, the air gap and the design.

Types of linear solenoids:

1. DC linear solenoids:
   These linear solenoids are operated with DC voltage and are the most commonly used design.
   They are characterized by simple control and easily controllable forces.
   The force increases with decreasing stroke distance, which is typical for electromagnetic systems.
2. AC linear solenoids:
   AC solenoids are designed for direct operation on AC voltages.
   They usually have special designs to reduce vibrations and humming noises.
   This design is often used in mains voltage applications.
3. Pull and push linear solenoids:
   Depending on the design, the linear solenoid can be primarily designed for tension or compression.
   Some designs allow both directions of movement, depending on the mechanical connection.
4. Proportional linear solenoids:
   Proportional solenoids enable infinitely variable control of the position or force depending on the current.
   They are used when not only on/off movements but also controlled intermediate positions are required, for example in valve technology or hydraulic systems.
5. Holding solenoids:
   Holding solenoids are a special form in which the armature can be held in its end position even after the current has been switched off, usually by permanent magnets. This saves energy, especially in holding applications.
6. Miniature and micro linear solenoids:
   These very small solenoids are used in electronics, medical technology and precision engineering applications.
   Despite their small size, they enable fast and precise movements.

Use of linear solenoids:

Linear solenoids are used in a variety of applications:

1. Valve control:
Gas, water, hydraulic and pneumatic valves.

2. Automation technology:
Sorting mechanisms, grippers, interlocks.

3. Medical technology:
Dosing systems, pumps, analysis devices.

5. Automotive engineering:
Locking systems, actuators.

6. Safety technology:
Door and locking systems.

7. Consumer goods:
Coffee machines, printers, household appliances.

Advantages of linear solenoids:

• Simple design: Few moving parts, resulting in high reliability.
• Fast response time: Very short switching and response times.
• Direct linear movement: No additional mechanics such as gears or spindles required.
• Compact design: Easy to integrate even in limited installation space.
• High switching cycle stability: Suitable for frequent actuation.
• Good controllability with proportional types: Force and position controllable via current.

Limits and challenges of linear solenoids:

• Linear solenoids usually deliver their highest force at the end point of the stroke.
• the force is not constant over the entire stroke, which must be taken into account in the design.
• In addition, continuous operation can cause the coil to heat up, which must be thermally controlled.

Linear solenoids are robust, versatile and economical actuators for generating linear movements. They work on the principle of electromagnetism and are available in numerous designs - from simple on/off solenoids to proportionally controlled systems. Thanks to their speed, reliability and simple integration, linear solenoids are indispensable in industry, medical technology, automotive engineering and consumer goods. Properly designed, they offer an efficient alternative to motorized or pneumatic linear actuators.

Here you will find an overview of the most important points to consider when purchasing linear solenoids:

Linear solenoids are electromagnetic actuators that convert electrical energy into linear motion. They are used in a wide range of applications - from valve controls and automation systems to medical technology and safety solutions. When purchasing linear solenoids professionally, it is not enough to focus solely on the price or the nominal force. A well-founded selection requires consideration of technical, mechanical, electrical and economic criteria to ensure that the linear solenoid works reliably, efficiently and economically in the long term.

• The first step is to precisely define the function of the linear solenoid. This should be clarified:
• Will the linear solenoid be used for pure back/forth movements or for proportional, stepless positioning?
• Which loads need to be moved or held?
• What stroke length and stroke path are required?
• What switching frequency or cycle duration is expected?
• An unclear specification can lead to the wrong type of solenoid being selected, resulting in malfunctions or premature wear.
• The choice of actuator type is crucial. The most common types are:
• DC solenoids: Easy to control, good force control.
• AC solenoids: For direct mains voltage, often with a special design to reduce humming noises.
• Proportional solenoids: Enable infinitely variable control of force or position, ideal for valves or dosing systems.
• Holding solenoids: Hold loads after switching off the current using permanent magnets, energy-saving.
• Miniature or micro solenoids: For compact, precise applications in medical technology or electronics.
• The choice depends heavily on the application - simple switching operations require different magnets than highly dynamic or precise positioning systems.
• The magnetic pulling force must be sufficient to move the load reliably. At the same time, the stroke length must be sufficient to achieve the desired movement. It is important to know the force curve, as linear solenoids usually develop their maximum force at the end point of the stroke.
• The mechanical load requirement must also be taken into account - weight, friction, damping and external forces affect the choice of solenoid.
• Depending on the design and cooling, linear solenoids have limits for cycle frequency and continuous operation. Professional purchasers must check:
• How many switching cycles per minute or hour are possible?
• Can the linear solenoid be used for continuous operation or only for intermittent operation?
• What thermal load is caused by frequent switching?
• For industrial applications or continuous processes, the operating time is a decisive criterion.
• The linear solenoid must be suitable for the existing electrical infrastructure. The following must be taken into account
• Operating voltage (DC or AC)
• Controllability (forward/backward or proportional)
• Starting and holding current
• Signal and interface requirements
• An incorrect power supply can cause performance losses or overheating.
• Solenoids must fit mechanically into the application. The following points play a role here:
• Mounting type and installation space.
• Alignment of armature, coil and moving load.
• Protection against external mechanical loads, vibrations or shocks.
• Compatibility with existing spring or return mechanisms.
• Professional linear solenoids must work reliably under real environmental conditions. The following must be taken into account:
• Temperature range and temperature drift.
• Moisture, dust, oil or chemical exposure.
• EMC immunity for industrial applications.
• Corrosion protection, protection class, e.g. IP65 or IP67.
• These factors determine the service life and reliability of the linear solenoid.
• Long-term and stable use requires the selection of a reliable manufacturer:
• Experience and references.
• Production quality and test documentation.
• Technical support and advice.
• Long-term availability of the products.
• A stable supplier is more important than the lowest price, especially for series products.
• In addition to the purchase price, total costs should also be considered:
• Energy consumption (especially for continuous operation).
• Maintenance and replacement cycles.
• Failure risks and production interruptions.
• A high-quality linear solenoid often pays for itself through lower maintenance costs and greater reliability.

The professional purchase of linear solenoids requires a holistic view of technology, mechanics, electrics and economy. The most important factors are the precise definition of the application, selection of the right design, suitable force and stroke parameters, environmental and installation conditions as well as manufacturer quality and life cycle costs. A correctly selected linear solenoid delivers reliable, fast and precise linear movements, minimizes downtimes, reduces maintenance costs and enables an economical and durable solution in industrial, medical technology, automation and safety applications.

Linear solenoids can be purchased from various suppliers. You will find comprehensive information on manufacturers and suppliers of Linear solenoids around the world on Exportpages.